Chevrolet - Silverado 1500 4wd - Workshop Manual - 2005 - 2005

Factory Workshop Manual Make Chevrolet Model Silverado 1500 4wd Engine and year V8-5.3L VIN Z Flex Fuel (2005) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 13 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 14 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 20 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 21 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 22 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 31 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 32 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 33 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 34 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 35 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 36 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 37 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 38 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 39 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 40 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 41 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 42 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 43 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 44 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 45 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 46 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 47 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 48 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 49 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 50 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 51 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 52 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 53 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 54 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 55 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 56 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 57 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 58 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 59 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 60 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 61 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 62 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 63 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 64 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 70 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 75 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 80 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 85 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 86 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 92 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 101 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 102 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 103 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 104 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 105 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 106 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 107 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 108 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 109 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 110 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 111 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 112 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 113 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 114 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 115 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 116 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 117 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 118 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 119 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 120 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 121 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 122 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 123 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 124 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 125 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 126 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 127 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 128 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 129 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 130 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 131 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 132 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 133 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 134 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 139 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 148 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 157 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 162 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 163 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 169 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 178 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 187 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 196 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 201 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 202 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 212 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 213 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 214 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 215 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 216 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 217 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 218 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 219 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 220 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 221 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 222 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 223 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 224 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 225 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 226 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 227 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 228 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 229 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 230 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 231 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 232 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 233 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 234 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 235 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 236 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 237 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 238 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 239 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 240 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 241 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 242 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 243 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 244 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 245 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 250 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations Instrument Panel (I/P) - Right Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 262 Global Positioning System Module: Diagrams Vehicle Communication Interface Module (VCIM) - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 263 Vehicle Communication Interface Module (VCIM) - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 264 Global Positioning System Module: Description and Operation VEHICLE COMMUNICATION INTERFACE MODULE (VCIM) The vehicle communication interface module (VCIM) is a 3-watt cellular device that allows the user to communicate data and voice signals over the National Cellular Network. It is powered by a fused, battery positive voltage circuit, connected through vehicle wiring to the 3-button assembly and the radio, and attached by means of coax cables to the cellular and navigation antennas. Ground for the module is accomplished by means of dedicated circuits that are routed with body wiring systems to chassis ground points. The module houses 2 modems, one to process global positioning system (GPS) data, and the other for cellular information. Satellites orbiting earth are constantly transmitting signals of their current location, from which the OnStar(R) system is able to pinpoint its own location. The navigation antenna receives these GPS signals and provides the data to the VCIM to be processed. The VCIM communicates with the rest of the vehicle over the class 2 serial data bus. Ignition state is determined by the VCIM through class 2 messaging. The module also has the capability of commanding the horn, door lock/unlock, and operating the exterior lamps using the class 2 serial data circuit. When an OnStar(R) keypress is made, a class 2 message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. After the audio system is muted, the OnStar(R) signals are transmitted to the audio system on the cellular telephone voice signal circuit, and returned to the module on the cellular telephone voice low reference circuit. The cellular modem connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 265 Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the Instrument Panel (I/P) upper trim panel. IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 2. Fully open the I/P storage compartment. 3. Disconnect the electrical connectors (2) from the Vehicle Communication Interface module (VCIM) (1). 4. Disconnect the coaxial cable (3) from the VCIM. 5. Remove the screws (1, 3) from the passenger side upper I/P support (2). 6. Remove the passenger side upper I/P support (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 266 7. Remove the screw (1) retaining the VCIM bracket to the I/P. 8. Remove the retainer from the VCIM bracket. 9. Remove the nuts holding the mounting brackets to the VCIM. 10. If necessary, move the cross-car duct forward slightly in order to make room for the removal of the module. 11. Remove the VCIM and bracket assembly from the I/P. 12. Remove the nuts (4) from the VCIM mounting brackets (2). 13. Remove the mounting brackets (2) from the VCIM (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 267 INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. 2. Ensure the nuts (3) are installed on the module mounting brackets (3). 3. Install the mounting brackets (2) to the VCIM (1). 4. Install the nuts (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the nuts to 2 N.m (18 lb in). 5. If necessary, move the cross-car duct forward slightly in order to make room for the installation of the module. 6. Install the VCIM and bracket assembly to the I/P. 7. Install the push in retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 268 8. Install the VCIM screw (1) to the I/P. Tighten the screws to 2 N.m (18 lb in). 9. Install the passenger side upper I/P bracket (2). 10. Install the I/P upper bracket screws (3). Tighten the screws (3) to 2 N.m (18 lb in). 11. Install the I/P upper bracket screws (1). Tighten the screws (1) to 50 N.m (37 lb ft). 12. Connect the coaxial cable (3) to the VCIM. 13. Connect the electrical connectors (2) to the VCIM. 14. Install the I/P trim panel. 15. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 269 system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 16. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 17. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 18. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 1. Tell the advisor that this vehicle has received a new VCIM. 2. Ask the advisor to add the new STID and the ESN to update the customer's account. 3. Follow any additional instructions from the OnStar(R) advisor. 4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. 19. The default language for voice recognition in the generation 5 OnStar(R) module is English. To change the language resident in the module, refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 278 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 279 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 280 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 286 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 287 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 288 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions Door Module: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 294 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 295 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 296 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 297 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 298 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 299 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 300 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 301 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 302 Door Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 303 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 304 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 306 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 307 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 308 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 309 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 310 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 311 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 312 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 313 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 314 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 315 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 316 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 317 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 318 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 319 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 320 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 321 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 322 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 323 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 324 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 325 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 326 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 327 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 328 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 329 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 330 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 331 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 332 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 333 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 334 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 335 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 336 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 337 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 338 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 339 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 340 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 341 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 342 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 343 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 344 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 345 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 346 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 347 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 348 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 349 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 350 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 351 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 352 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 353 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 354 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 355 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 356 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 357 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 358 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 359 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 360 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 361 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 362 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 363 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 366 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 367 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 368 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 369 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 370 Door Module: Connector Views Front Passenger Door Module (FPDM) - C5 (Heated Seat Switch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 372 Driver Door Module (DDM) - C1 (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 373 Driver Door Module (DDM) - C2 (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Driver Door Module (DDM) - C3 (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 375 Driver Door Module (DDM) - C4 (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 376 Driver Door Module (DDM) - C5 (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 377 Passenger Door Module (PDM) - C1 (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 378 Passenger Door Module (PDM) - C2 (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 379 Passenger Door Module (PDM) - C3 (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 380 Passenger Door Module (PDM) - C4 (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 381 Passenger Door Module (PDM) - C5 (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Page 382 Door Module: Testing and Inspection DOOR CONTROL MODULE PROGRAMMING AND SETUP Driver Door Module After replacing the driver door module (DDM), perform the Service Programing Procedure. See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS) - How to Use Passenger Door Module After replacing the passenger door module (PDM), perform the following programing and setup procedures: - Service Programming System (SPS) See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS) - How to Use - Transmitter Programming in Keyless Entry See: Testing and Inspection/Programming and Relearning/Remote Keyless Entry (RKE) - Transmitter Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 391 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 397 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 400 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 401 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. 4. Install the module retaining screws (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 410 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 416 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 417 Power Seat Control Module: Diagrams Memory Seat Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 418 Memory Seat Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 419 Memory Seat Module - C3 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 420 Memory Seat Module - C3 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 421 Memory Seat Module - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 05-08-50-008 > Aug > 05 > Interior - Intermittent Seat Heater Operation Seat Heater Control Module: Customer Interest Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 05-08-05-008 > Aug > 05 > Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: Customer Interest Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 05-08-50-008 > Aug > 05 > Interior - Intermittent Seat Heater Operation Seat Heater Control Module: All Technical Service Bulletins Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 05-08-05-008 > Aug > 05 > Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: All Technical Service Bulletins Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 446 Sunroof / Moonroof Module: Diagrams Sunroof Control Module C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 447 Sunroof Control Module C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 457 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 463 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 464 Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 465 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (ECBM) C1 Electronic Brake Control Module (ECBM) C2 (8600 GVW or Less w/Rear Disc Brakes Electronic Brake Control Module (ECBM) C2 (Over 8600 GVW or Rear Drum Brakes Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 466 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 467 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 4. Disconnect the chassis electrical connectors from the EBCM. 5. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 468 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 7. Disconnect the BPMV electrical connector from the EBCM. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 469 1. Connect the BPMV electrical connector to the EBCM. 2. Install the EBCM to the BPMV. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the new screws (1) in the EBCM (2). Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 470 4. connect the chassis electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations COOLING FAN RELAYS LF Of Engine Compartment Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 475 Location View Application Table The Cooling Fan 1, Cooling Fan 2, Cooling Fan 3, relays are located in the Fuse Block Underhood - Cooling Fan (10 Series). The Fuse Block - Underhood - Cooling Fan (10 Series) is located in the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module (CCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 480 Cruise Control Module (CCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 490 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 491 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 497 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 503 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 504 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 509 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 515 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 521 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 522 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 523 Blower Motor Control Processor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Description and Operation Speedometer Module: Description and Operation SPEEDOMETER The instrument panel cluster (IPC) displays the vehicle speed on the analog speedometer based on the vehicle speed signal from the powertrain control module (PCM). The PCM converts the data from the vehicle speed sensor to a 4,000 pulses/mile signal. The IPC uses the vehicle speed signal circuit from the PCM in order to calculate the vehicle speed. The speedometer defaults to 0 km/h (0 mph) if a malfunction in the vehicle speed signal circuit exists. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations LR Of The Engine Compartment (With RPO Code 5Y0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Diagrams > Emergency Vehicle Roof Lamp Relay (With RPO Code 5Y0) Emergency Vehicle Roof Lamp Relay (With RPO Code 5Y0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Diagrams > Emergency Vehicle Roof Lamp Relay (With RPO Code 5Y0) > Page 535 Roof Beacon Relay (With RPO Code 5G4/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 544 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 545 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 551 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 552 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 558 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 559 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 560 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 561 Relay Box: Locations Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 562 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 563 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 566 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 567 Relay Box: Diagrams Junction Block - Rear Lamps - C2 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 568 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 569 Relay Box: Diagrams Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 570 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 571 Relay Box: Diagrams Junction Block - Rear Lamps - C4 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 572 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 573 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 574 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 575 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 576 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 577 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 578 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 579 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 580 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 581 Junction Block - I/P - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 582 Junction Block - I/P - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 583 Junction Block - I/P - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 584 Junction Block - I/P - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 585 Junction Block - I/P - C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 586 Junction Block - I/P - C8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 587 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 588 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 589 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 590 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 591 Relay Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 592 Relay Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 593 Relay Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 594 Relay Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 595 Relay Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 596 Relay Block - I/P C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 597 Relay Block - I/P C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 598 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 599 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 600 Relay Block - I/P C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 601 Relay Block - I/P C10 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 604 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 605 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 606 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 607 Relay Box: Application and ID Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 608 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 609 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 612 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 613 Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 614 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 615 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 616 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 617 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications > Page 623 Body Control Module (BCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 626 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 627 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 628 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 629 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 630 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 631 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 632 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 633 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 634 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 635 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 636 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 637 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 638 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 639 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 640 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 641 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 642 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 643 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 644 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 645 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 646 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 647 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 648 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 649 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 650 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 651 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 652 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 653 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 654 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 655 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 656 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 657 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 658 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 659 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 660 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 661 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 662 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 663 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 664 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 665 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 666 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 667 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 668 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 669 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 670 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 671 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 672 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 673 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 674 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 675 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 676 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 677 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 678 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 679 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 680 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 681 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 682 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 683 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 684 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 685 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 686 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 687 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 688 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 689 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 690 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 691 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 692 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 693 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 694 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 695 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 697 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 698 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 701 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 702 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 704 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 705 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 706 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Body Control Module (BCM) - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Body Control Module (BCM) - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Body Control Module: Electrical Diagrams Body Control System Diagrams Body Control System Diagram 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Body Control System Diagram 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Body Control System Diagram 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Body Control System Diagram 4 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Body Control System Diagram 4 (2 Of 2) Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Computer/Integrating Systems Computer/Integrating Systems Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Power, Ground, DLC and Splice Pack SP 205 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 717 Splice Pack SP 207 Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Door Control Module Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 718 Door Control Module Diagram 1 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 719 Door Control Module Diagram 1 (2 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 720 Door Control Module Diagram 2 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 721 Door Control Module Diagram 2 (2 Of 2) Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagram can be found via their numbers at Vehicle Locations. See: Locations Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION BCM FUNCTIONS The body control module (BCM) performs multiple body control functions. The BCM can control devices directly connected to its outputs based on input information. The BCM evaluates this information and controls certain body control systems by commanding outputs on or off. The BCM control inputs can be: Sensors and switches that are directly connected to the BCM - Class 2 serial data received from other control modules connected to the class 2 serial data link. The BCM is also capable of controlling other vehicle systems that are not directly wired to the BCM. The BCM does this by sending specific messages on the class 2 serial data link. The control module capable of performing the required function will respond to the BCM message. The BCM controls these functions: Audible warnings, refer to Audible Warnings Description and Operation in Instrument Panel, Gages and Console - Automatic door locks, refer to Power Door Locks Description and Operation in Doors - Automatic headlamp control, refer to Exterior Lighting Systems Description and Operation in Lighting Systems - Interior lighting, refer to Interior Lighting Systems Description and Operation in Lighting Systems - Keyless entry (AUO option), refer to Keyless Entry System Description and Operation in Keyless Entry. - Passlock theft deterrent, refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Retained Accessory Power (RAP), refer to Retained Accessory Power (RAP) Description and Operation POWER MODE The BCM is the power mode master (PMM). Refer to Power Mode Description and Operation for more information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 724 Body Control Module: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The serial data communication among the control modules is performed through multiple serial data communication links. The class 2 serial data line is always present. The high speed GMLAN or controller area network (CAN) may be present for different vehicle options. The data link connector (DLC) allows a scan tool to communicate with the modules on class 2 or high speed GMLAN serial data lines. In order for the scan tool to communicate with the modules on high speed GMLAN link, a CANdi module is needed. The CANdi module behaves as an interface between the scan tool and the high speed GMLAN data link. The CAN is used for functional communication only, among the modules connected to it. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 - Class 2 signal at terminal 2 - High speed GMLAN serial data bus (+) at terminal 6 - High speed GMLAN serial data bus (-) at terminal 14 CLASS 2 SERIAL DATA LINE Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The class 2 serial data line on this vehicle is a star configuration. The powertrain control module (PCM) has an additional class 2 serial data circuit to body control module (BCM). If one of the class 2 serial data circuits to the PCM opens, communication will not be interrupted. The following modules communicate on the class 2 serial data line: The audio amplifier (AMP), w/UQ7 and Y91 - The body control module (BCM) - The communication interface module (OnStar(R)), w/UE1 - The digital radio receiver (DRR), w/U2K - The driver door module (DDM) - The electronic brake control module (EBCM) - The generator battery control module (GBCM) - The HVAC control module - The hybrid control module (HCM), w/HP2 - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The memory seat module (MSM), w/AN3 - The passenger door module (PDM) - The powertrain/engine control module (PCM/ECM) - The radio - The rear seat audio (RSA) controller, w/UK6 - The rear seat entertainment (RSE) assembly w/U42 - The rear wheel steering control module (RWSCM), w/NYS - The remote playback device - CD player (CDX), w/U1S - The transfer case shift control module (TCSCM), w/NP1/NP8 - The transmission control module (TCM), w/M74 The class 2 serial data line allows a scan tool to communicate with these modules for testing purposes, checking for DTCs, and to activate/enable/disable functions. These class 2 serial data circuits are bussed together via 2 splice packs: SP205-Located behind the instrument panel (I/P) near the headlamp switch connector. - SP207-Located in the I/P harness. Refer to Computer/Integrating Systems Component Views. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 725 HIGH SPEED GMLAN SERIAL DATA LINE (PHT) The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit through the CANdi module. The serial data is transmitted on two twisted wires that allow speed up to 500 Kbps. The twisted pair is terminated with two 120-ohm resistors, one is internal to the engine control module (ECM) and the other is internal to the energy storage control module (ESCM). The resistors are used to reduce noise on the high speed GMLAN bus during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level which is approximately 2.5 volts is considered a recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes adds 1 volt to high speed GMLAN serial data bus (+) and subtracts 1 volt from high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles's functionality has been requested. A virtual network is supported by virtual devices which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Failsofting is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a "heartbeat" of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped as a code against the physical device. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The powertrain control module (PCM) and hybrid control module (HCM) are functionally communicating on both class 2 and high speed GMLAN data links. However the diagnostic communication of the above modules with the scan tool is performed on class 2 data link only. All DTCs set by the high speed GMLAN modules, including HCM, are reported by the PCM on class 2. Data displaying, output controls and programming of the control modules connected to high speed GMLAN only, is performed through high speed GMLAN link. The GMLAN serial data communications circuit is in a linear topology. The following modules are connected to the link, in order from DLC to the end of the linear configuration: The energy storage control module (ESCM) - The starter/generator control module (SGCM) - The electro-hydraulic power steering (EHPS) - The hybrid control module (HCM) - The powertrain control module (PCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 726 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION SERIAL DATA POWER MODE On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle the PMM is the body control module (BCM). The BCM uses 3 signals from the ignition switch. These are the Ignition 0, Ignition 1, and Accessory. To determine the correct power mode the BCM uses: The state of these signals - The sequence of switch closures received by the BCM - The status of the engine run flag The chart indicates the power modes detected and transmitted by the BCM: FAIL-SAFE OPERATION Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the BCM fail to send a power mode message. The fail-safe plan covers modules with discrete ignition signal inputs as well as those modules using exclusively serial data control of power mode. SERIAL DATA MESSAGES The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid BCM message until they receive the engine status from the PCM. If the BCM fails, the modules monitor the serial data circuit for the engine run flag serial data. If the engine run flag serial data is true, indicating that the engine is running, the modules fail-safe to Run. In this state the modules and their subsystems can support all operator requirements. If the engine run flag serial data is false, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. DISCRETE IGNITION SIGNALS Those modules that have discrete ignition signal inputs also remain in the state dictated by the last valid BCM message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, B+, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 voltage, the modules will fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 727 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 730 Body Control Module: Symptom Related Diagnostic Procedures - Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description and Operation - Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Scan Tool Does Not Power Up See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with Class 2 Device See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With High Speed GMLAN Device - Power Mode Mismatch See: Power Mode Mismatch - Retained Accessory Power (RAP) On After Timeout See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) Inoperative Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 731 Steps 1-6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 732 Steps 1-6 Power Mode Mismatch POWER MODE MISMATCH CIRCUIT DESCRIPTION Normal vehicle class 2 communications and module operations will not begin until the system power mode has been identified. Discrete wires from the ignition switch contacts are monitored by the power mode master (PMM) module in order to determine the correct power mode. The PMM communicates the system power mode to all class 2 modules on the class 2 serial data line. Refer to Body Control System Description and Operation to identify which module is the PMM and the applicable power mode look up table. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 733 Steps 1-6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 734 Steps 7-14 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 735 Step 15 The numbers below refer to the step numbers on the diagnostic table. 7. This step tests for battery voltage on the signal circuits that are not required. 8. This step tests for no battery voltage on the required signal circuits. 9. If any ignition switch parameters that should be inactive in the present ignition switch position are active, 2 ignition switch signal circuits may be shorted together. 10. This step eliminates open circuits as the cause of the malfunction. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 736 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Battery Voltage: The scan tool displays 0.0-16.0 volts. The battery voltage input represents the system voltage measured at the BCM ignition feed input. (Driver/Passenger) Door Ajar Switch (w/o DDM or w/o PDM)): Input from the respecting door indicating door status. Ignition Accessory: Input from ignition switch Accessory circuit. Used to determine power mode. Hot in ACC and ON. Ignition 0: Input to the control module from the ignition switch indicating the Ignition 0 position. Switch closed (HOT) in ignition switch positions UNLOCK, ACC, ON, and START Ignition 1: Input to the control module from the ignition switch indicating the Ignition 1 position. Switch closed (HOT) in ignition switch positions ON and START. Key in Ignition: Input from ignition switch indicating that the ignition key is inserted into the ignition switch. HOT with key in ignition switch. Julian Date of Build: The day of the year when module was built. Left Rear/Rear Cargo Door Ajar Switch: Input from the left rear/rear cargo door showing the state of it. Right Rear Door Ajar Sw.: Input from the right rear door showing the state of it. SWC Switch Power: Indicates the state of the supply voltage to the steering wheel controls supply voltage. SWC Switch Voltage: Indicates the steering wheel controls supply voltage. Year Module Built: The year when module was built. 8 Digit GM Part Number: The module's part number. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 737 Scan Tool Data List Scan Tool Output Controls Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function "Request BCM Info. for SPS", then connect the scan tool to the SPS terminal and follow the instructions on the screen. Refer to Service Programming System (SPS) in Programming and Setup. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 740 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cables. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the body control module (BCM) from the sliding bracket. INSTALLATION PROCEDURE 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 741 4. Install the knee bolster. 5. Connect the negative battery cables. 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations THROTTLE ACTUATOR CONTROL MODULE Throttle Actuator Control (TAC) Module The Throttle Actuator Control Module (TAC) is located in the left rear of the engine compartment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 745 Electronic Throttle Control Module: Diagrams C1 Throttle Actuator Control (TAC) Module C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 746 C2 Throttle Actuator Control (TAC) Module C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 747 Electronic Throttle Control Module: Service and Repair Electronic Throttle Actuator Control Module Replacement Removal Procedure 1. Disconnect the instrument panel (I/P) harness electrical connector (2). 2. Release the red connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1). 4. Remove the throttle actuator control (TAC) module nuts. 5. Remove the TAC module. Installation Procedure 1. Install the TAC module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 748 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the TAC module nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Connect the engine wiring harness electrical connector (1). 4. Install the red CPA retainer. 5. Connect the I/P harness electrical connector (2). 6. Refer to Control Module References for programming and setup information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 757 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 758 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 759 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 760 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 761 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 762 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 763 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 769 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement Engine Control Module: Customer Interest Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement > Page 774 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 780 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 785 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 794 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 795 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 796 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 797 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 798 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 799 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 800 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls Battery Lamp ON After PCM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls Battery Lamp ON After PCM Replacement > Page 805 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 811 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 817 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 826 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 827 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 828 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 829 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 830 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 831 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 832 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 833 Powertrain Control Module (PCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 836 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 837 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 838 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 839 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 840 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 841 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 842 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 843 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 844 Engine Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 845 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 846 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 847 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 848 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 849 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 850 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 851 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 852 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 853 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 854 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 855 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 856 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 857 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 858 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 859 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 860 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 861 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 862 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 863 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 864 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 865 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 866 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 867 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 868 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 869 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 870 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 871 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 872 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 873 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 874 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 875 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 876 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 877 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 878 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 879 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 880 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 881 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 882 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 883 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 884 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 885 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 886 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 887 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 888 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 890 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 891 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 892 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 893 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 894 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 895 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 896 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 897 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 898 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 899 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 900 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 901 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 902 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 903 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 904 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 905 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 906 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 908 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 909 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 910 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 911 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 912 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 913 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 914 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 915 Powertrain Control Module (PCM) C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 916 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 917 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 918 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 919 Powertrain Control Module (PCM) C2 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 922 - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. MIL Request: Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 923 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 924 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. Removal Procedure IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. If equipped with regular production option (RPO) NYS, remove the harness ground clip from the PCM cover. 4. If equipped with RPO HP2, remove the hybrid control module (HCM). 5. If vehicle is NOT equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 925 6. If vehicle is equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. 7. Loosen the PCM electrical connector bolts (2). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 8. Disconnect the PCM electrical connectors. 9. Release the spring latch from the PCM. 10. Release the PCM mounting tabs from the PCM. 11. Remove the PCM. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 926 1. Install the PCM.Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Tighten the bolts to 8 N.m (71 lb in). 5. If vehicle is equipped with RPO HP2, install the PCM cover. 6. If vehicle is NOT equipped with RPO HP2, install the PCM cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 927 7. If equipped with RPO HP2, install the HCM. 8. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 9. Connect the negative battery cable. 10. If a NEW PCM was installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 933 Fuse Block - Underhood Label The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 934 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Underhood Fuse Block The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 937 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 938 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 939 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 940 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 941 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 942 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 944 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 945 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 946 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 947 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 948 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 949 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 950 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 952 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 953 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 954 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 955 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 956 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 957 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 958 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 959 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 960 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 961 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 962 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 963 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 964 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 965 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 966 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 967 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 968 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 969 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 970 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 971 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 972 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 973 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 974 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 975 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 976 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 977 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 978 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 979 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 980 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 981 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 982 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 983 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 984 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 985 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 986 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 987 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 988 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 989 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 990 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 993 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 995 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 996 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 997 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 998 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 999 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1012 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1013 Fuel Pump (FP) Relay - Secondary (w/Dual Tanks) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The PCM 1 fuse - The ETC/ECM fuse - The INJ 1 fuse - The INJ 2 fuse - The SBA fuse, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 1018 Steps 1-7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 1019 Steps 8-17 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 1020 Steps 18-26 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 1021 Steps 27-31 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Inflatable Restraint Side Impact Module - Left (Seat) Below Driver Seat - SIR Wiring Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Inflatable Restraint Side Impact Module - Left (Seat) > Page 1027 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1028 Air Bag Control Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1029 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1030 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and requests the instrument panel cluster (IPC) to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will request the IPC to turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1031 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the drivers seat. 3. Remove the driver side door sill plate. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. 7. Disconnect the SDM wiring harness connector (1) from the SDM (3). 8. Remove the SDM mounting fasteners. 9. Remove the SDM from the vehicle. 10. Repair the fasteners using the following procedure: 1. Remove the stripped nut and discard the nut. 2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 3. Condition the floor panel attaching surface where the new stud is to be installed. 4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 5. Migweld the stud at the drilled holes from above or below the floor pan, as required. 6. Apply body sealer GM P/N 9984248 around any exposed openings. 7. Install a new fastener GM P/N 11515933. IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1032 mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface. 2. Install the SDM (3) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten fasteners to 10 N.m (89 lb in). 5. Connect the SDM wiring harness connector (1) to the SDM. 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 8. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 9. Install the door sill plate. 10. Install the driver seat. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. IMPORTANT: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations STARTER RELAY Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1037 Fuse Block - Underhood Label Fuse Block - Underhood Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1038 The Starter Relay is located on the Fuse Block - Underhood. The Fuse Block - Underhood is located on the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams Steering Control Module: Diagrams Rear Wheel Steering Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 1044 Rear Wheel Steering Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 1045 Rear Wheel Steering Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 1046 Rear Wheel Steering Module - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 1049 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering Lifting and Jacking Notice in Service Precautions. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Connect the electrical connectors to the module. 4. Program the control module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 1050 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering). See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls Shared Diagnostic Trouble Codes Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 1071 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 1074 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 Control Module: Diagrams NVG 246-NP8 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 1077 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 1078 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 1079 Control Module: Diagrams NVG 263-NP1 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 1080 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 1081 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 1084 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 1085 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 1086 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window Power Window Control Module: Service and Repair Module Replacement - Rear Power Window MODULE REPLACEMENT - REAR POWER WINDOW REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the water deflector. 3. Remove the window glass. 4. Remove the window sash. 5. Remove the glass weatherstrip. 6. Remove the module from the door. INSTALLATION PROCEDURE 1. Install the module to the door. 2. Install the glass weatherstrip. 3. Install the window sash. 4. Install the window glass. 5. Install the water deflector. 6. Install the trim panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window > Page 1092 Power Window Control Module: Service and Repair Module Replacement - Front Power Window MODULE REPLACEMENT - FRONT POWER WINDOW REMOVAL PROCEDURE 1. Raise and support the window. 2. Remove the trim panel. 3. Remove the water deflector. 4. Disconnect the wiring harness from the window motor assembly. 5. Remove the 2 bolts holding the window to the regulator. 6. Remove the bolts from the window regulator. 7. Remove the window regulator assembly from the door folding both sides together. INSTALLATION PROCEDURE 1. Install the regulator to the door. 2. Install the bolts to the window regulator. NOTE:Refer to Fastener Notice in Service Precautions. Tighten the bolts to 9 N.m (80 lb in). 3. Align the window to the regulator and install the bolts holding the window to the regulator. Tighten the bolts to 9 N.m (80 lb in). 4. Connect the wiring harness to the window motor assembly. 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the window operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Upper Steering Column Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 1098 Passlock Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Diagrams Door Latch Assembly (Key Cylinder Switch) - Driver C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (Base Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 1110 Door Lock Switch - Passenger (Base Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures Power Door Lock Switch: Procedures Accessory Switch Replacement ACCESSORY SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP trim bezel. 2. Grasp the accessory switch assembly and pull outwards to remove the button assembly. 3. Disconnect the electrical connectors for the switches in the assembly. 4. Remove the switches and the button assembly. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the switches in the assembly 2. Install the accessory switch assembly into the IP till it snaps into place. 3. Install the IP trim bezel. Switch Replacement - Door Lock and Side Window - Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1113 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1114 2. Install the switch panel bezel and module to the door panel. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Switch Replacement - Door Lock and Side Window - Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1115 1. Remove the front door trim panel. 2. Remove the screw (2) that retains the switch panel bezel (1) to the front door trim panel. 3. Remove the switch panel bezel from the door panel using a flat-bladed tool. 4. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 5. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1116 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module into the door trim panel. 3. Install the screw (2) that retains the switch panel bezel (1) to the front door trim panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screw (2) to 2 N.m (18 lb in). 4. Install the front door trim panel. 5. Perform the necessary setup and programming procedures. Refer to Door Control Module Programming and Setup in Vehicle Control Systems. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1117 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1118 Installation Procedure 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Switch Replacement - Door Lock and Side Window - Passenger Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1119 Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Remove the front door trim panel. 2. Remove the screw (2) that retains the switch panel bezel (1) to the front door trim panel. 3. Remove the switch panel bezel from the door panel using a flat-bladed tool. 4. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 5. Remove the door module from the switch panel bezel. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1120 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module into the door trim panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw (2) that retains the switch panel bezel (1) to the front door trim panel. Tighten the screw (2) to 2 N.m (18 lb in). 4. Install the front door trim panel. 5. Perform the necessary setup and programming procedures. Refer to Door Control Module Programming and Setup. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair Power Mirror Switch: Service and Repair ACCESSORY SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP trim bezel. 2. Grasp the accessory switch assembly and pull outwards to remove the button assembly. 3. Disconnect the electrical connectors for the switches in the assembly. 4. Remove the switches and the button assembly. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the switches in the assembly 2. Install the accessory switch assembly into the IP till it snaps into place. 3. Install the IP trim bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations Power Seat Motor Position Sensor: Locations Driver Seat - With RPO Code AG1, AN3 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 1127 Driver Seat - With RPO Code AG1, AN3 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1130 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1131 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1132 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1133 Power Seat Motor Position Sensor: Diagrams Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1134 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1135 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1136 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1137 Seat Rear Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1138 Seat Recliner Motor Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 1147 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 1153 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 1159 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 1160 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 1166 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 1167 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1168 Power Seat Switch: Locations Driver Seat - With RPO Code AG1, AN3 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1169 Passenger Seat - With RPO Code AG2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1170 Driver Seat Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1171 Front Passenger Seat (With RPO Code AN3) Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Adjuster Switch Power Seat Switch: Diagrams Seat Adjuster Switch Seat Adjuster Switch - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Adjuster Switch > Page 1174 Seat Adjuster Switch - Driver (With RPO Code AG1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Adjuster Switch > Page 1175 Seat Adjuster Switch - Front Passenger (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Adjuster Switch > Page 1176 Power Seat Switch: Diagrams Seat Bolster/Lumbar Switch Seat Bolster/Lumbar Switch - Driver (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Adjuster Switch > Page 1177 Seat Bolster/Lumbar Switch - Front Passenger (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. INSTALLATION PROCEDURE 1. Install the lumbar switch to the power seat switch bezel. 2. Install the lumbar switch screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Seat Switch Bezel Replacement SEAT SWITCH BEZEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the screws retaining the power seat switch bezel. 2. Disconnect the electrical connectors. 3. Remove the lumbar support switch. 4. Remove the power seat adjuster switch assembly. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1180 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten the screws to 2 N.m (18 lb in). Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1181 Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1182 Power Seat Switch: Removal and Replacement Seat Switch Bezel Replacement Seat Switch Bezel Replacement Removal Procedure 1. Remove the screws retaining the power seat switch bezel. 2. Disconnect the electrical connectors. 3. Remove the lumbar support switch. 4. Remove the power seat adjuster switch assembly. Installation Procedure 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten the screws to 2 N.m (18 lb in). Seat Switch Replacement - Power Seat Switch Replacement - Power Removal Procedure 1. Remove the power seat switch bezel from the seat. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1183 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Driver Door Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 1187 Passenger Door Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) > Page 1190 Front Passenger Door Module (FPDM) - C5 (Heated Seat Switch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) > Page 1191 Heated Seat Switch - Front Passenger (FPDM C5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) > Page 1192 Memory/Heated Seat Switch - Driver (DDM C5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front HEATED SEAT SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch assembly in order to remove the switch. 4. Remove the front seat heater switch assembly. INSTALLATION PROCEDURE 1. Install the front seat heater switch assembly to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch assembly. 3. Install the front trim panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front > Page 1195 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear HEATED SEAT SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. INSTALLATION PROCEDURE 1. Install the switch to the console panel. 2. Install the retaining screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams > Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams > Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) > Page 1200 Memory/Heated Seat Switch - Driver (DDM C5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams > Page 1201 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 1205 Sunroof Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 1206 Sunroof / Moonroof Switch: Service and Repair SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the roof console assembly. 2. Disconnect the electrical connector. 3. Remove the switch by unsnapping from roof console assembly. INSTALLATION PROCEDURE 1. Install the switch to roof console assembly by snapping into place. 2. Connect the electrical connector. 3. Install the roof console assembly. 4. Synchronize the sunroof motor. Refer to Sunroof Motor/Actuator Synchronization. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Brake Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 1211 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Using needle nose pliers, compress the locking tabs at the opposite side of the master cylinder. 3. Remove the fluid level sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 1212 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Brake Pressure Differential Switch With RPO JC4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams Brake Pedal Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Park Brake Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams Traction Control Switch: Diagrams Traction Control Switch (NW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 1225 Traction Control Switch: Service and Repair Traction Control Switch Replacement (Stabilitrak) Removal Procedure 1. Remove the Instrument Panel (I/P) bezel. 2. Gently lift the retaining tabs (2) and remove the stabilitrak switch (3) from the I/P assembly (1). 3. Disconnect the harness connector from the stabilitrak switch. Installation Procedure 1. Connect the harness connector to the stabilitrak switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 1226 2. Install the stabilitrak switch (3) into the I/P assembly (1) 3. Ensure that the switch is secure into both retaining tabs (2). 4. Install the I/P bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 1235 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 1241 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1242 Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1243 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) LF Wheel Speed Sensor (WSS) RF Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1244 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Front (4 Wheel Drive) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2) shown on the 1500 Series. 4. Remove the Wheel Speed Sensor (WSS) cable mounting clip from the knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Remove the WSS cable electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1245 8. Remove the WSS mounting bolt. 9. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the WSS (5) from the hub/bearing assembly (4) shown on the 2500/3500 series. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to sensor installation. 4. Install the WSS (5) into the hub/bearing assembly (4) shown on the 2500/3500 series. Ensure that the sensor is seated flat against the hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1246 5. Notice: Refer to Fastener Notice in Service Precautions. Install the WSS mounting bolt. Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. 9. Connect the WSS cable electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1247 10. Install the brake rotor (2) shown on the 1500 Series. 11. Install the tire and wheel. 12. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1253 Left Side Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1254 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1255 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1256 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (3). 3. Remove the oil level sensor from the oil pan. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the oil level sensor to the oil pan. Tighten the sensor to 13 Nm (115 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair > Page 1261 2. Connect the oil level sensor electrical connector (3). 3. Fill the engine oil. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required ^ J41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 1271 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J41712 or equivalent, install the oil pressure sensor. Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Air Temperature Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1276 Ambient Air Temperature Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1277 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Upper Left B-Pillar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1281 Air Temperature Sensor Assembly - Inside Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1282 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1283 7. Install the left windshield garnish molding. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations Discharge Air Temperature Sensor / Switch: Locations Air Temperature Sensors - Upper Left And Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1287 Air Temperature Sensor - Lower Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1288 Air Temperature Sensor - Lower Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1289 Discharge Air Temperature Sensor / Switch: Diagrams Air Temperature Sensor - Lower Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1290 Air Temperature Sensor - Lower Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1291 Air Temperature Sensor - Upper Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1292 Air Temperature Sensor - Upper Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor - Upper Right Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor - Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the I/P upper trim panel. 2. Disconnect the electrical connector (1) from the upper right air temperature sensor (2). 3. Remove the upper right air temperature sensor (1) from the air distributor duct (3). INSTALLATION PROCEDURE 1. Install the upper right air temperature sensor (1) to the air distributor duct (3). 2. Connect the electrical connector (1) from the upper right air temperature sensor (2). 3. Install the I/P upper trim panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor - Upper Right > Page 1295 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor - Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the upper left air temperature sensor (2) from the air distributor duct (1). 2. Disconnect the electrical connector (3) from the upper left air temperature sensor (2). INSTALLATION PROCEDURE 1. Install the upper left air temperature sensor (2) to the air distributor duct (1). 2. Connect the electrical connector (3) to the upper left air temperature sensor (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor - Upper Right > Page 1296 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor - Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the lower left air temperature sensor (1). 2. Remove the lower left air temperature sensor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the lower left air temperature sensor (1) to the HVAC module (2). 2. Connect the electrical connector to the lower left air temperature sensor (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor - Upper Right > Page 1297 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor - Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the I/P lower closeout panel. 2. Remove the right floor duct. 3. Remove the center console. 4. Disconnect the electrical connector from the lower right air temperature sensor (1). 5. Remove the lower right air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the lower right air temperature sensor (1). 2. Connect the electrical connector to the lower right air temperature sensor (1). 3. Install the center console. 4. Install the right floor duct. 5. Install the I/P lower closeout panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch > Page 1303 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 1304 A/C Low Pressure Switch And A/C Accumulator Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 1305 A/C Low Pressure Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Ambient Light/Sunload Sensor Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1309 Ambient Light/Sunload Sensor Assembly (With RPO Code CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1310 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the sun load sensor (2) from the upper trim panel. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim panel. 3. Install the I/P upper trim panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations Instrument Panel Switches - LH Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver Door Latch Assembly (Door Jamb Switch) - Driver - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver > Page 1319 Door Latch Assembly (Door Jamb Switch) - Driver C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver > Page 1320 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Passenger Door Latch Assembly (Door Jamb Switch) - Passenger - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver > Page 1321 Door Latch Assembly (Door Jamb Switch) - Passenger C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver > Page 1322 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver > Page 1323 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams Fuel Pump/Sender Assembly - Primary Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 1327 Fuel Pump/Sender Assembly - Secondary Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System (Pickup and Utility) Fuel Gauge Sender: Description and Operation Fuel System (Pickup and Utility) FUEL SENDER ASSEMBLY The front fuel sender on dual tank applications consists of the following major components: - The fuel level sensor - The fuel tank fuel pump module - The fuel strainer - The fuel filter The rear fuel sender on dual tank applications consists of the following major components: - The fuel level sensor (4) - The FTP sensor (1) - The rear fuel pump (2) The fuel sender assembly on single tank applications consists of the following major components: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System (Pickup and Utility) > Page 1330 - The fuel level sensor - The fuel tank pressure (FTP) sensor - The fuel tank fuel pump module - The fuel strainer - The fuel filter Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System (Pickup and Utility) > Page 1331 Fuel Gauge Sender: Description and Operation Fuel System (Cab Chassis) FUEL SENDER ASSEMBLY The fuel sender assembly consists of the following major components: - The fuel sender assembly (2) - The fuel strainer (3) - The fuel pump (4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1332 Fuel Gauge Sender: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 44402 Fuel Tank Sending Unit Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect fuel lines from the sending unit, if required. 3. Using J 44402, remove the sending unit lock ring. 4. Remove the sending unit and seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 5. Clean the sending unit sealing surfaces. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1333 1. Install a NEW sending unit seal. 2. Align the tab, and install the sending unit. 3. Using J 44402, install the sending unit lock ring. 4. Connect fuel lines to the sending unit, if required. 5. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Diagrams Ambient Air Temperature Sensor (With RPO Code DF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Diagrams > Page 1337 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the push pin retainer from the sensor mounted on the radiator support brace. 3. Disconnect the electrical connector from the sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sensor. 2. Install the sensor to the radiator support brace and install the push pin retainer. 3. Install the radiator grille to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Park Brake Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation Water In Fuel Sensor: Description and Operation WATER IN FUEL The instrument panel cluster (IPC) illuminates the WATER IN FUEL message in the driver information center (DIC) when the powertrain control module (PCM) detects a low signal from the water in fuel sensor. The IPC receives a class 2 message from the PCM requesting illumination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light/Sunload Sensor Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Ambient Light Sensor (With RPO Code CJ3) Ambient Light Sensor (With RPO Code CJ3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Ambient Light Sensor (With RPO Code CJ3) > Page 1350 Ambient Light/Sunload Sensor Assembly (With RPO Code CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 1351 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Stop Lamp Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1355 Stop Lamp Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1356 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). INSTALLATION PROCEDURE 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations Instrument Panel Switches - LH Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations > Page 1360 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Multifunction Accessory Switch Multifunction Accessory Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Multifunction Accessory Switch > Page 1365 Combination Switch: Diagrams Turn Signal Multifunction Switch Turn Signal Multifunction Switch - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Multifunction Accessory Switch > Page 1366 Turn Signal Multifunction Switch - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Multifunction Accessory Switch > Page 1367 Turn Signal Multifunction Switch - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Multifunction Accessory Switch > Page 1368 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver Door Latch Assembly (Door Jamb Switch) - Driver - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver > Page 1373 Door Latch Assembly (Door Jamb Switch) - Driver C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver > Page 1374 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Passenger Door Latch Assembly (Door Jamb Switch) - Passenger - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver > Page 1375 Door Latch Assembly (Door Jamb Switch) - Passenger C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver > Page 1376 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver > Page 1377 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Fog/Driving Lamp Switch: Locations Instrument Panel Switches - LH Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 1381 Accessory Switch Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch Assembly Replacement - Front Fog Lamp and Cargo Lamp Fog/Driving Lamp Switch: Service and Repair Lamp Switch Assembly Replacement - Front Fog Lamp and Cargo Lamp LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch Assembly Replacement - Front Fog Lamp and Cargo Lamp > Page 1384 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear FOG LAMP SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair INSTRUMENT PANEL (I/P) COMPARTMENT LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lower the instrument panel storage compartment door by pressing in the tab. 2. With one hand holding the plunger of the switch, use a small screw driver to push in the tabs on each side while pulling outwards. 3. Pull the switch assembly from the I/P. 4. Disconnect the electrical connector. 5. Remove the bulb (1). INSTALLATION PROCEDURE 1. Install the bulb (1) into the socket. 2. Connect the electrical connector. 3. Install the switch until the tabs (1) click in place. 4. Close the compartment door. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Alignment Switch > Component Information > Service and Repair Headlamp Alignment Switch: Service and Repair HEADLAMP LEVELING SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the head lamp leveling switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the head lamp leveling switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Instrument Panel Switches - LH Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1394 Headlamp Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1395 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Steering Wheel And Column Sub-System Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Turn Signal Multifunction Switch - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1402 Turn Signal Multifunction Switch - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1403 Turn Signal Multifunction Switch - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1404 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1410 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1411 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1412 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1413 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1419 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1420 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1421 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1422 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1423 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1424 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1425 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1426 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1427 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1428 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1429 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1430 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1431 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1432 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1433 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1434 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1435 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1436 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1437 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1438 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1439 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1440 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1441 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1442 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1443 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1444 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1445 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1446 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1447 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1448 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1449 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1450 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1451 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1455 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1459 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1464 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1465 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1471 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1472 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1473 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1474 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1475 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1476 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1477 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1478 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1479 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1480 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1481 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1488 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1489 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1494 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 1496 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 1497 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations CAMSHAFT POSITION SENSOR The Camshaft Position Sensor (CMP) is located on the top rear center of engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1506 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1507 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1508 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1509 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1510 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1511 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1512 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1513 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1514 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1515 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1516 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1517 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1518 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1519 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1520 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1521 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1522 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1523 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1524 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1525 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1526 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1527 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1528 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1529 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1530 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1531 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1532 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1533 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1534 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1535 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1536 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1537 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1538 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1539 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1540 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1541 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1542 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1543 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1544 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1545 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1546 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1547 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1548 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1549 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1550 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1551 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1552 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1553 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1554 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1555 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1556 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1557 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1558 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1559 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1560 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1561 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1562 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1563 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1564 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1565 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1566 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1567 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1568 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1569 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1570 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1571 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1572 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1573 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1574 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1575 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1576 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1577 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1579 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1580 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1581 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1582 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1583 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1584 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations SEO Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1591 Left Side Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1592 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1593 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1594 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1599 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1600 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1601 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1602 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1603 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1604 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1605 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1606 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1607 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1608 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1609 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1610 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1611 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1612 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1613 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1614 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1615 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1616 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1617 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1618 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1619 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1620 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1621 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1622 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1623 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1624 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1625 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1626 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1627 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1628 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1629 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1630 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1631 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1632 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1633 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1634 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1635 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1636 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1637 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1638 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1639 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1640 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1641 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1642 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1643 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1644 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1645 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1646 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1647 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1648 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1649 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1650 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1651 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1652 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1653 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1654 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1655 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1656 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1657 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1658 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1659 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1660 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1661 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1662 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1663 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1664 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1665 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1666 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1667 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1668 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1669 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1670 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1671 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1673 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1674 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 Crankshaft Position (CKP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1676 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1679 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1680 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel System (Cab Chassis) Fuel Level Sensor: Description and Operation Fuel System (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (I/P) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the powertrain control module (PCM). The PCM calculates the total fuel level in both tanks. The instrument panel (I/P) fuel gage displays the total fuel level in both fuel tanks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel System (Cab Chassis) > Page 1686 Fuel Level Sensor: Description and Operation Fuel System (Pickup and Utility) FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 1689 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 1690 1. Install the fuel level sensor. 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 1691 4. Install the fuel level sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 1692 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 44402 Fuel Tank Sending Unit Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect fuel lines from the sending unit, if required. 3. Using J 44402, remove the sending unit lock ring. 4. Remove the sending unit and seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 5. Clean the sending unit sealing surfaces. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 1693 assure that the fuel strainer does not block full travel of the float arm. 1. Install a NEW sending unit seal. 2. Align the tab, and install the sending unit. 3. Using J 44402, install the sending unit lock ring. 4. Connect fuel lines to the sending unit, if required. 5. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1697 Fuel Tank Pressure (FTP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1698 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1699 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1703 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1704 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1705 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1711 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1712 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1714 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1715 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1716 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1719 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1720 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1721 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1722 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1734 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1774 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1775 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1776 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1777 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1778 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1779 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1780 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1781 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1782 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1783 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1784 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1785 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1786 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1787 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1788 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1789 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1790 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1791 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Top Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1795 Manifold Absolute Pressure (MAP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1796 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1797 1. Install the MAP sensor (1). 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required ^ J41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 1804 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J41712 or equivalent, install the oil pressure sensor. Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 1813 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 1819 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 1820 HO2S Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1823 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1824 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1825 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1826 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1827 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1828 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1829 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1830 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1831 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1832 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1833 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1834 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1847 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1848 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1857 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1862 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1863 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1864 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1865 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1866 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1892 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1893 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1894 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1895 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1896 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1897 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1898 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1899 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1900 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1901 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1902 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 1905 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 1906 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 1907 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 1908 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 1909 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 1910 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 1911 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 1916 Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 1919 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 1922 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 1923 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 1924 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 1925 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 1926 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1931 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1932 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1933 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1934 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1940 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1941 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1942 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1943 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1944 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1945 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1946 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1947 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1948 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1949 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1950 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1951 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1952 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1953 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1954 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1955 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1956 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1957 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1958 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1959 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1960 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1961 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1963 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1969 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1971 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1972 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1973 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1974 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1975 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1976 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1977 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1978 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1979 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1980 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1981 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1982 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1983 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1984 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1985 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1986 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1987 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1988 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1989 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1990 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1991 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1992 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1993 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1994 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1995 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1996 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1997 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1998 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1999 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2000 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2001 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2002 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2003 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2004 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2005 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2006 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2007 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2008 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2009 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2010 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2011 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2012 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2013 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2014 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2015 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2016 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2017 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2018 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations Fuel Composition Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 2022 Fuel Composition Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 2023 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The fuel composition sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the powertrain control module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing -40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 41/2 percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 2024 Steps 1-5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 2025 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the fuel composition sensor electrical connector. 4. Remove the fuel line retainers (1). 5. Disconnect the fuel composition sensor fuel lines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 2026 6. Remove the fuel composition sensor bracket nuts. 7. Remove the fuel composition sensor. 8. If required, remove the fuel composition sensor bolts and remove the sensor from the bracket. INSTALLATION PROCEDURE 1. If required, install the fuel composition sensor to the bracket and install the bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten bolts to 10 N.m (89 lb in). 2. Install the fuel composition sensor. 3. Install the fuel composition sensor bracket nuts. Tighten nuts to 17 N.m (13 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 2027 4. Connect the fuel composition sensor fuel lines. 5. Install the fuel line retainers (1). 6. Connect the fuel composition sensor electrical connector. 7. Lower the vehicle. 8. Use the following procedure in order to inspect for leaks: - Turn the ignition ON, with the engine OFF, for 2 seconds. - Turn the ignition OFF for 10 seconds. - Turn the ignition ON, with the engine OFF. - Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations CAMSHAFT POSITION SENSOR The Camshaft Position Sensor (CMP) is located on the top rear center of engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2034 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2035 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2036 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2037 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2038 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2039 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2040 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2041 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2042 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2043 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2044 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2045 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2046 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2047 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2048 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2049 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2050 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2051 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2052 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2053 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2054 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2055 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2056 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2057 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2058 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2059 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2060 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2061 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2062 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2063 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2064 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2065 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2066 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2067 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2068 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2069 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2070 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2071 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2072 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2073 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2074 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2075 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2076 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2077 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2078 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2079 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2080 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2081 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2082 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2083 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2084 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2085 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2086 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2091 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2092 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2093 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2094 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2095 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2096 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2097 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2103 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2104 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2105 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2106 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2108 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2109 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2110 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2111 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2112 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2117 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2143 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2144 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2147 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2148 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2149 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2150 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2151 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2152 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2153 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2154 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2157 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2158 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2159 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2160 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2161 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2162 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2163 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2164 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2165 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2166 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2167 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2168 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2169 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2170 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2171 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2172 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2173 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2174 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2175 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2176 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2177 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2178 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2179 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2180 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2181 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2182 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2183 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2184 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2185 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2186 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Crankshaft Position (CKP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2194 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2197 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2198 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2230 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2231 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2232 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2234 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2247 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2249 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2252 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2253 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2260 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2261 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2262 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2263 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2264 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2267 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2268 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2270 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2271 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2272 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2273 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2274 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2275 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2276 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2277 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2278 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2279 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2280 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2281 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2282 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2283 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2284 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Center Of The I/P - Accessory Switches (Except 10 Searies And Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 2289 Inflatable Restraint I/P Module Disable Switch (Except 10 Series And Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > I/P Module Disable Switch (HD Model Pickups) Air Bag Deactivation Switch: Description and Operation I/P Module Disable Switch (HD Model Pickups) INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH (HD MODEL PICKUPS) The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the inflatable restraint sensing and diagnostic module (SDM) to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicators located on the I/P module disable switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > I/P Module Disable Switch (HD Model Pickups) > Page 2292 Air Bag Deactivation Switch: Description and Operation I/P Module Disable Switch INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the passenger presence system (PPS) module to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicator and the PASSENGER AIR BAG ON/OFF indicators located on the rear view mirror. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 2293 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT INSTRUMENT PANEL (I/P) MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel trim bezel. CAUTION: Refer to SIR Caution in Service Precautions. 2. Remove the I/P module switch from the lower right opening of the switch plate panel. 3. Disconnect the I/P module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the I/P module switch electrical connector. 2. Install the I/P module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Front End Sensors Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor Impact Sensor: Diagrams Inflatable Restraint Front End Sensor Inflatable Restraint Front End Sensor - Left (With RPO Code ALO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor > Page 2299 Inflatable Restraint Front End Sensor - Right (With RPO Code ALO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor > Page 2300 Inflatable Restraint Front End Sensor (With RPO Code HVY) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor > Page 2301 Inflatable Restraint Passenger Seat Belt Tension Retractor Sensor (With RPO Code ALO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Sensor > Page 2302 Inflatable Restraint Passenger Presence System (PPS) Sensor (With RPO Code ALO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Passenger Seat Belt Tension Retractor Sensor Impact Sensor: Description and Operation Passenger Seat Belt Tension Retractor Sensor INFLATABLE RESTRAINT PASSENGER SEAT BELT TENSION RETRACTOR SENSOR The seat belt tension retractor sensor is used to enhance the passenger presence system (PPS) when an infant car seat is properly restrained on the front outboard passenger seat. The seat belt tension retractor sensor is a 3-wire potentiometer mounted on the lower seat belt anchor and provides an input to the PPS module. When an infant car seat is properly restrained on the front passenger seat, the seat belt is tightly secured through the infant car seat. The seat belt pulls on the tension sensor and changes the voltage signal to the PPS module. The PPS module uses the voltage signal to help determine if a tightly belted infant car seat is installed. The PPS uses the inputs from the seat belt tension retractor sensor and the PPS pressure sensor to determine if the I/P module should be suppressed or enabled. The PPS monitors the seat belt tension retractor sensor circuits and sets DTC 023 if a fault is detected. To determine what DTCs have been set by the PPS, the Tech 2 is used to command the SDM to request the PPS to flash the DTCs using the PASSENGER AIR BAG ON/OFF indicators located on the rearview mirror. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Passenger Seat Belt Tension Retractor Sensor > Page 2305 Impact Sensor: Description and Operation Front End Sensors INFLATABLE RESTRAINT FRONT END SENSORS The front end sensors are equipped on vehicles to supplement the SIR system performance. The front end sensors are electronic and are not part of the deployment loops, but instead provide inputs to the sensing and diagnostic module (SDM). The front end sensors can assist in determining the severity of some frontal collisions. The SDM uses the input from the front end sensors to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Page 2306 Impact Sensor: Service and Repair INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Disconnect the electrical connector. 3. Remove the connector position assurance (CPA) from the connector. 4. Remove the sensor bolt. 5. Remove the sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface (1). 2. Point the arrow on the sensor toward the front of the vehicle. IMPORTANT: Refer to SIR Service Precautions. 3. Install the sensor (2) horizontally to the radiator support. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 9 N.m (79 lb in). 4. Connect the electrical connector to the sensor (2). 5. Install the CPA. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Driver Seat Belt Buckle Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2310 Passenger Seat Belt Buckle (with RPO Code ALO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2311 Seat Belt Buckle Switch: Diagrams Seat Belt Switch - Driver Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2312 Seat Belt Switch - Passenger (with RPO Code ALO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 2317 Seat Occupant Sensor: Service and Repair INFLATABLE RESTRAINT PASSENGER PRESENCE SYSTEM REPLACEMENT - FRONT REMOVAL PROCEDURE CAUTION: Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. The bladder, the pressure sensor, the seat cushion, and the control module are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly. 1. Remove the seat cushion trim cover and pad. 2. Disconnect the electrical connectors. 3. Remove the bolts that retain the electronic control unit (ECU) (1) from the bottom of the passenger seat cushion frame. 4. Remove the pressure switch (2) from the bottom of the passenger seat cushion frame. 5. Remove the push-in retainers (1) that hold the bladder to the seat cushion frame. 6. Remove the inflatable restraint passenger presence system from the seat. INSTALLATION PROCEDURE 1. Install the inflatable restraint passenger presence system to the seat. 2. Install the push-in retainers (1) that hold the bladder to the seat cushion frame. 3. Install the pressure sensor (2) to the bottom of the passenger seat cushion frame. 4. Install the bolts that retain the (ECU) (1) to the bottom the passenger seat cushion frame. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 2318 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 2 N.m (18 lb in). 5. Connect the electrical connectors. 6. Install the seat cushion trim cover and pad. 7. Re-zero the inflatable restraint passenger presence system. Refer to Passenger Presence System Programming and Setup in Programming and Setup. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Passenger Presence Components - Under Front Passenger Seat Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2322 Seat Sensor/Switch: Diagrams Inflatable Restraint Seat Position Switch - Left (With RPO Code ALO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2323 Inflatable Restraint Seat Position Switch - Right (With RPO Code ALO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2324 Seat Sensor/Switch: Description and Operation INFLATABLE RESTRAINT SEAT POSITION SENSORS (SPS) The seat position sensor (SPS) is used to determine the proximity of a front driver or passenger seat position with respect to the frontal air bag. The SPS interfaces with the SDM. The state of the SPS allows the SDM to disable stage 2 of the frontal air bag for a front seat that is forward of a forward/rearward point in seat track travel. The SPS is a Hall effect sensor that is mounted on the outboard seat track of both the driver and passenger seats. The seat track includes a metal bracket that shunts the SPS magnetic circuit creating 2 states of seat position. The shunted state represents a rearward seat position. The non-shunted state represents a forward position. The SPS provides 2 current ranges, one range for the shunted state and a second range for a non-shunted state. These 2 states are inputs to the SDM, state 1 (shunted) being the rearward threshold and state 2 (non-shunted) being the forward threshold. When the SDM receives input from a SPS that state 1 threshold is reached (seat is rearward) the SDM will not disable stage 2 deployment, if required by the deployment sensors. When state 2 threshold is reached (seat is forward) the SDM will disable stage 2 deployment on the side the seat is forward. The SDM monitors the SPS circuit and if a fault is detected the SDM will set codes B0083 or B0084 and defaults to disabling stage 2 frontal deployment. This will only default on the side of the vehicle the sensor has a fault. It's important to understand that the SPS is secondary to the passenger presence system (PPS) and the manual I/P module disable switch. If either one of these devices are in the disable mode, the passenger air bag will not deploy regardless of the SPS status. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2325 Seat Sensor/Switch: Service and Repair INFLATABLE RESTRAINT SEAT POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the passenger or driver's seat from the vehicle. 2. Disconnect the electrical connector from the seat position sensor. 3. Drill out the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. CAUTION: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 4. Remove the seat position sensor from the seat adjuster track bracket. INSTALLATION PROCEDURE 1. Install the seat position sensor to the seat adjuster bracket. 2. Install the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 3. Connect the electrical connector to the seat position sensor. 4. Install the passenger or driver's seat to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Start Switch Clutch Start Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 2331 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 2332 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 2333 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Rear Wheel Steering Switch > Component Information > Diagrams Rear Wheel Steering Mode Select Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Rear Wheel Steering Switch > Component Information > Diagrams > Page 2339 Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 2344 Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 2345 Rear Wheel Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 2346 Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering, Vehicle Lifting. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the electrical connector (1). 3. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 4. Remove the rear wheel position sensor retaining bolts (3). 5. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. Refer to Steering Gear Actuator and Cover Replacement. 6. Important: Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 2347 Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Lower the vehicle. 7. Perform a four wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2352 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2353 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2354 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2355 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2356 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2357 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2358 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2359 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 2360 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 2366 Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 2367 Rear Wheel Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 2368 Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering, Vehicle Lifting. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the electrical connector (1). 3. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 4. Remove the rear wheel position sensor retaining bolts (3). 5. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. Refer to Steering Gear Actuator and Cover Replacement. 6. Important: Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 2369 Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Lower the vehicle. 7. Perform a four wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams > Page 2373 Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2379 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Automatic Transmission Shift Lock Control Component Views Lower Steering Column Components Lower Steering Column Components 1 - A/T Shift Lock Control Actuator 2 - Steering Column Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 2389 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Fluid Pressure Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 2392 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 2393 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 2394 Fluid Pressure Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 2397 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2398 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2399 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2400 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Remove the remaining valve body bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2401 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2402 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Notice: Refer to Fastener Notice in Service Precautions. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2403 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2404 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Do not install the transmission fluid indicator stop bracket and bolt at this time.Install but do not tighten the valve body bolts which retain only the valve body directly.Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2405 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2406 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2407 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E > Page 2412 Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 2415 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 2416 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 2417 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 2422 Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 2425 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2428 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2429 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2430 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2431 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2432 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Speed Sensor: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 2437 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 2438 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 2439 Transmission Speed Sensor: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E Transmission Speed Sensor: Diagrams 4L80-E/4L85-E Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 2442 Automatic Transmission Output Shaft Speed (AT OSS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 2443 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Speed Sensor: Service and Repair 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2446 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2447 Transmission Speed Sensor: Service and Repair 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2448 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2449 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2450 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E > Page 2455 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Temperature Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 2458 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 2459 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 2460 Transmission Temperature Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2461 Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 Transmission Speed Sensor: Locations NV 3500 Manual Transmission Component Views Manual Transmission - NV 3500 Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 2467 Transmission Speed Sensor: Locations NV 4500 Manual Transmission Component Views Manual Transmission - NV 4500 Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 2468 Transmission Speed Sensor: Locations ZF S6-650 Manual Transmission Component Views Manual Transmission - ZF S6-650 Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 2471 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 2472 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 2475 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 2476 Transmission Speed Sensor: Service and Repair NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 2477 3. Connect the VSS electrical connector (3).Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 2478 Transmission Speed Sensor: Service and Repair ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. If equipped with the 6.6L engine , disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 2479 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine , connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 Four Wheel Drive Selector Switch: Locations NVG 246-NP8 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 > Page 2485 Four Wheel Drive Selector Switch: Locations NVG 263-NP1 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 Four Wheel Drive Selector Switch: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 2488 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 2489 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 2490 Four Wheel Drive Selector Switch: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 2491 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 2492 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 2493 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Gear Sensor/Switch: Service and Repair NVG 246-NP8 Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to Neutral prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench. 3. Remove and discard 2 screws (2) from the motor cover. 4. Remove and discard 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 2498 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat-tipped screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 2499 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler gear are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 2500 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 2501 Gear Sensor/Switch: Service and Repair NVG 261-NP2 Transfer Case Gear Indicator Switch Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the gear indicator switch electrical connector (2). 3. Remove the gear indicator switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the gear indicator switch. ^ Tighten the switch to 27 Nm (20 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 2502 2. Connect the gear indicator switch electrical connector (2). 3. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 2503 Gear Sensor/Switch: Service and Repair NVG 263-NP1 Encoder Motor Sensor Replacement Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 2504 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 2505 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 2506 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Transfer Case Shift Control Switch Replacement Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 2515 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 2521 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 2533 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2536 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2537 Speed Sensor: Service and Repair NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2538 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2539 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2540 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2541 Speed Sensor: Service and Repair NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2542 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2543 Speed Sensor: Service and Repair NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2544 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2552 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2554 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2555 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2556 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2557 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2558 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2562 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2563 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2564 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2565 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2566 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2567 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2568 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2569 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2570 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2571 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2573 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2574 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2575 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2576 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2577 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2578 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2579 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2583 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2584 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2585 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2586 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2587 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2588 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2589 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2590 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2591 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2592 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2593 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2594 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2595 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2596 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2597 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2598 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2599 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2600 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2601 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2602 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2604 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2605 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2606 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2607 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2609 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2610 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2611 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2612 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2613 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2614 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2615 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2617 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2618 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2620 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 Power Window Switch: Connector Views Window Switch - LR (Crew Cab Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2627 Window Switch - RR (Crew Cab Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door Power Window Switch Replacement - Rear Door Removal Procedure 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. Installation Procedure 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 2630 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 2631 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 2632 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Remove the screw (2) that retains the switch panel bezel (1) to the front door trim panel. 3. Remove the switch panel bezel from the door panel using a flat-bladed tool. 4. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 5. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 2633 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module into the door trim panel. 3. Install the screw (2) that retains the switch panel bezel (1) to the front door trim panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screw (2) to 2 N.m (18 lb in). 4. Install the front door trim panel. 5. Perform the necessary setup and programming procedures. Refer to Door Control Module Programming and Setup in Vehicle Control Systems. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Windshield Washer Reservoir Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2638 Washer Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2639 Washer Fluid Level Switch: Service and Repair WASHER SOLVENT CONTAINER LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Using a small flat-bladed tool, remove the washer solvent container level sensor (1) and seal (2) from the container. INSTALLATION PROCEDURE 1. Position the washer solvent container level sensor (1) and the seal (2) to the container by pressing in until fully seated. 2. Install the washer solvent container. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2645 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2646 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2647 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2648 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2649 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2650 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2651 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2652 Alignment: Technical Service Bulletins Steering/Suspension - Revised Alignment Specifications Bulletin No.: 05-03-07-006 Date: May 31, 2005 SERVICE MANUAL UPDATE Subject: Revised Wheel Alignment Specifications Models: 2005 Chevrolet Silverado 2005 GMC Sierra This bulletin is being issued to revise the Wheel Alignment Specifications in the Wheel Alignment sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2653 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2654 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2655 The information shown has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2656 Alignment: Technical Service Bulletins Steering/Suspension - Revised Caster/Camber Adjustment Info - Revised Front Caster and Camber Adjustment Procedure # 02-03-07-002A - (Mar 24, 2005) Models: 1999-2000 Cadillac Escalade 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Express, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999 GMC Suburban 1999-2005 GMC Savana, Sierra, Yukon, Yukon XL, Yukon XL Denali This bulletin is being revised to add model years and clarify the information. Please discard Corporate Bulletin Number 02-03-07-002 (Section 03 - Suspension). When performing a wheel alignment on any of the above vehicles, please refer to the Front Caster and Camber Adjustment Procedure in SI before contacting the GM Technical Assistance Center (TAC) with issues concerning adjustments, caster out-of-spec, etc. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 2659 Alignment: Specifications Wheel Alignment Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 2660 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 2661 Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2662 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2663 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Definition: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Wheel alignment ^ Unbalanced steering gear The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2664 Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure Alignment: Service and Repair Trim Height Inspection Procedure Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Make sure the vehicle is on a level surface, such as a alignment rack. 2. Remove the alignment rack floating pins. 3. Set the tire pressures to the pressure shown on the certification label. 4. Check the fuel level. Add additional weight if necessary to simulate a full tank. 5. Make sure the rear compartment is empty except for the spare tire. 6. Close the doors and hood. Z Height Measurement Important: K models only the Z height must be adjusted before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use a adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Important: All dimensions are measured vertical to the ground. Cross vehicle Z heights should be within 12 mm (0.47 inch) to be considered correct. Place hand on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (2) down to the lower corner (5) of the steering knuckle (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and the lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the highest and the lowest measurements. Refer to Trim Height Specifications. Z Height Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 2667 1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1) into the nut increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement Important: There are no specified trim heights specifications on leaf spring vehicles because it is not an adjustable feature. The height of the suspension will depend on the option content of the vehicle as well as the aftermarket equipment that is placed on the vehicle. The measurements are used for comparison only and should be within 15 mm with the vehicle at curb and no accessories. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Allow the vehicle to settle into position. 3. Important: Measure the metal to metal contact points of the rear axle to the frame on the inboard side of the leaf springs. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true D height dimension number is the average of the highest and the lowest measurements. 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension Refer to Front Coil Springs Replacement or Torsion Bar Replacement in Front Suspension. ^ Sagging rear leaf/coil springs Refer to Leaf Spring Replacement in Rear Suspension. ^ Worn rear suspension components, such as leaf spring bushings Refer to Spring Bushing Replacement in Rear Suspension. ^ Improper tire inflation Refer to Tire Inflation Pressure Specifications. ^ Improper weight distribution ^ Collision damage Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 2668 Alignment: Service and Repair Measuring Wheel Alignment (W/Rear Wheel Steering) Measuring Wheel Alignment (w/Rear Wheel Steering) Learn Wheel Alignment After replacement of the handwheel position sensor, rear wheel position sensor, or rear wheel steering control module it is necessary to perform the learn wheel alignment procedure. Alignment Procedure Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications then perform the learn alignment procedure. Learn Wheel Alignment Procedure 1. Turn ignition to ON position, with the engine ON. 2. Install the scan tool. 3. Center the steering wheel. 4. Lift the rear of the vehicle off the ground ensuring the rear wheels are centered. 5. Go to the Learn Alignment menu choice in the scan tool. Follow the prompts on the scan tool. Important: When prompted by the scan tool you must turn the steering wheel a full 90 degrees to the left and a full 90 degrees to the right and then to center and hold. If this step is not done properly then it is possible to cause a false DTC for the steering wheel position sensor. 6. Press the continue button. 7. Use the scan tool to clear all rear wheel steering DTCs. (W/O Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 2669 Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 2670 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment 1. Important: Caster measurements or valves must be compensated for the measured frame angle. Caster is relative to frame, the caster values must be compensated for the measured frame angle by using a digital protractor or equivalent on a flat portion of the frame in front of the rear tire. 2. Frame angle is positive when higher in the rear. Measure both sides of the frame and take an average from those measurements. Then add the average frame angle to the caster reading when making adjustments. 3. Frame angle is negative when lower in the rear. Measure both sides of the frame and take an average from the measurements. Then subtract the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 2671 average frame angle from the caster reading when making adjustments. 4. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. For an accurate reading, do not push or pull on the tires during the alignment process. 5. Determine the caster angle (2). Be sure to compensate for frame angle where required. 6. Determine the positive camber (2) or negative camber (3) angle. 7. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 8. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice in Service Precautions. 9. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met.When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. ^ Tighten the cam nuts to 190 Nm (140 ft. lbs.). 10. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications. When the caster and camber are within specifications, adjust the toe. Refer to Front Toe Adjustment. Front Toe Adjustment Front Toe Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 2672 1. Loosen the jam nut on the tie rod (2). 2. Rotate the inner tie rod (1) to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 68 Nm (50 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Rear Toe Adjustment Rear Toe Adjustment 1. Loosen the jam nut on the tie rod (1). 2. Rotate the inner tie rod to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 65 Nm (48 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................385-425 kPa (55-62 psi) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2679 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2680 Steps 1-4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2681 Steps 5-13 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2694 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2700 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2701 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2702 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2708 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. Refer to Fuel Pressure Gage Installation and Removal. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. .........................................................1,000 ohms per ft Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2712 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2713 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: IMPORTANT: The Melco(R) spark plug wires MUST be used only with the Melco(R) coils and bracket, like wise the Delphi(R) spark plug wires MUST be used only with Delphi(R) coils and bracket. The components are NOT interchangeable. 4. The Melco(R) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(R) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. 6. The Melco(R) (1) ignition coil is a square design. 7. The Delphi(R) (2) ignition coil is a round design. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2714 8. The Melco(R) ignition coil bracket (1) is a square design. 9. The Delphi(R) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ............................................ 1.02 mm (0.04 inches) Spark Plug Torque ............................................. ................................................................................................................................... 15 Nm (11 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2718 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................... AC 25171803 (NGK 12567759) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2719 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2720 - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2721 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2722 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Spark plug gap: 1.016 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. - Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 5. Install the spark plug wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2726 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Check the compression again and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2731 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2732 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Accessory Drive Belt Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Accessory Drive Belt > Page 2735 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2736 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2739 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2740 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2741 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2742 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2743 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2744 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2745 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2746 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2747 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2748 Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2749 An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2750 Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2751 the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body, or suspension component, or other item(s) on the vehicle may cause the squeal noise. If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying their load(s), making sure they are operating to their maximum capacity. An overcharged Air Conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further in this table 3. The squeal may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt(s) or an accessory drive component. With the drive belt(s) removed the water pump will not operate and the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2752 engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This test is to verify that an accessory drive component(s) does not have a seized bearing. With the belt(s) removed, test the bearings in the accessory drive component(s) for smooth operation. Also test the accessory drive component(s) with the engine operating by varying the load on the accessory drive component(s) to verify that the component(s) is operating properly. 5. This test is to verify that the drive belt(s) tensioner(s) are not operating properly. If the drive belt tensioner(s) are not operating properly, proper belt tension may not be achieved to keep the drive belt(s) from slipping which could cause a squealing noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 8. Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys. Drive Belt Vibration Drive Belt Vibration Diagnosis Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2753 Diagnostic Aids The accessory drive components may have an affect on engine vibration. An overcharged Air Conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the drive belt(s). 6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange. 9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known, good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2754 Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine. If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their loads, making sure they are operating to their maximum capacity. An overcharged Air Conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2755 The number(s) below refer to the step(s) in the diagnostic table. 3. This test is to verify that the whine is being caused by the accessory drive component(s). Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory Drive Belt: Service and Repair Drive Belt Replacement - Accessory Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Loosen the air cleaner outlet duct clamps at the following locations: ^ The throttle body ^ The Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 2. Disconnect the radiator inlet hose clip from the outlet duct. 3. Remove the air cleaner outlet duct. 4. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 5. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt (1). 6. Remove the belt (1) from the pulleys and the drive belt tensioner. 7. Slowly release the tension on the drive belt tensioner. 8. Remove the breaker bar and socket and from the drive belt tensioner bolt. 9. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt (1) under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 2758 7. Inspect the drive belt (1) for proper installation and alignment. 8. Align the arrow (2) at the throttle body end of the duct with the throttle body attaching stud (1). 9. Install the air cleaner outlet duct. 10. Connect the radiator inlet hose clip to the outlet duct. Notice: Refer to Fastener Notice in Service Precautions. 11. Tighten the air cleaner outlet duct clamps at the following locations: ^ The throttle body ^ The MAF/IAT sensor Tighten the clamps to 4 Nm (35 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 2759 Drive Belt: Service and Repair Drive Belt Replacement - Air Conditioning Drive Belt Replacement - Air Conditioning Removal Procedure 1. Remove the accessory drive belt. 2. Raise and suitably support the vehicle. 3. Remove the engine shield bolts. 4. Remove the engine shield. 5. Install a ratchet into the Air Conditioning (A/C) belt tensioner adapter opening. 6. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt. 7. Remove the A/C belt from the pulleys. 8. Slowly release the tension on the A/C belt tensioner. 9. Remove the ratchet from the A/C belt tensioner. 10. Clean and inspect the belt surfaces of all the pulleys. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 2760 Installation Procedure 1. Install the A/C belt around the crankshaft balancer. 2. Install a ratchet into the A/C drive belt tensioner adapter opening 3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the tensioner. 4. Install the A/C belt over the idler pulley. 5. Install the A/C belt around the A/C compressor pulley. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the ratchet from the A/C belt tensioner. 8. Inspect the A/C belt for proper installation and alignment. 9. Install the engine shield. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the engine shield bolts. Tighten the bolts to 20 Nm (15 ft. lbs.). 11. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 2761 12. Install the accessory drive belt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 2772 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2778 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2779 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2780 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This Article has been updated by bulletin #PIT3330, dated December 22, 2004. Condition/Concern: A customer may inquire about the availability of the passenger compartment air filter. Recommendation/Instructions: Starting in 2003 model year, the passenger compartment air filter is no longer available as a factory option. With the redesigned HVAC case, there is no longer a cavity for the filter. The GM parts catalog indicates there is a replacement filter available; however, there is no provision for it. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 2792 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 2793 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 2794 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 2795 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions MIL ON/DTC P0446 Stored In ECM > Page 2801 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions MIL ON/DTC P0446 Stored In ECM > Page 2802 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions MIL ON/DTC P0446 Stored In ECM > Page 2803 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions MIL ON/DTC P0446 Stored In ECM > Page 2804 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E Fluid Filter - A/T: Service and Repair 4L60-E/4L65-E Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. 9. Remove the oil pan and the gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2809 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2810 4. Install the oil pan and NEW gasket. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Refer to Transmission Fluid Checking Procedure and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2811 Fluid Filter - A/T: Service and Repair 4L80-E/4L85-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2812 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2813 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 2814 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2820 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. Refer to Fuel Pressure Gage Installation and Removal. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Fuel System (Pickup and Utility) Fuel Pump Pickup Filter: Description and Operation Fuel System (Pickup and Utility) FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Fuel System (Pickup and Utility) > Page 2825 Fuel Pump Pickup Filter: Description and Operation Fuel System (Cab Chassis) FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2830 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2831 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Installation Refrigerant Filter: Service and Repair Installation AIR CONDITIONING (A/C) REFRIGERANT FILTER INSTALLATION TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, ACDelco P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 2836 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 2837 Refrigerant Filter: Service and Repair Replacement AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 2838 1. Coat the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 2839 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the air cleaner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Using the J 43181 disconnect the heater hose from the heater core inlet. 3.1. Install the J 43181 to the heater core pipe. 3.2. Close the tool around the heater core pipe. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 4. Reposition the inlet heater hose clamp from the engine. 5. Remove the inlet heater hose from the engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2845 6. Remove the inlet heater hose mounting bolt. 7. Remove the inlet heater hose from the engine. 8. Remove the inlet heater hose. INSTALLATION PROCEDURE 1. Install the inlet heater hose. 2. Install the inlet heater hose to the engine. 3. Reposition the inlet heater hose clamp to the engine. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the inlet heater hose mounting bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2846 5. Install the inlet heater hose to the engine. 6. Connect the heater hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 7. Install the air intake tube. 8. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2847 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core outlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the outlet heater hose from the engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2848 6. Remove the outlet heater hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. 2. Install the outlet heater hose to the engine. 3. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 06-01-38-002 > Mar > 06 > A/C - Hiss Noise From Instrument Panel Hose/Line HVAC: Customer Interest A/C - Hiss Noise From Instrument Panel Bulletin No.: 06-01-38-002 Date: March 17, 2006 TECHNICAL Subject: A/C System Refrigerant Hiss Noise (Replace Liquid Line) Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, T, Z, B, U, N, G - RPOs LU3, LR4, LM7, L59, L33, LQ4, LQ9, L18) and Air Conditioning (RPOs CJ2, CJ3 and C69) Condition Some customers may comment on a hiss noise coming from the instrument panel. The noise has also been described as sounding like a gurgle or water spattering. The noise occurs when the Air Conditioning (A/C) compressor engages and may continue for 5 to 10 seconds after the compressor disengages or the A/C system is turned off. The noise is most noticeable when the vehicle is at idle or is being driven at low speeds. The noise is undetectable after about one minute when the A/C system has been turned off or the vehicle has been turned off. Cause This condition may be caused by the expanding refrigerant as it passes through the orifice tube. Correction Technicians are to verify that the customer concern is only as described in the condition statement above. If the customer concern is a refrigerant hiss noise, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly, and all other possible sources of this noise are eliminated, then technicians are to replace the A/C liquid line. Use the proper part number as described in the parts information box below. Verify that the noise has been eliminated and that the A/C system operates normally. Parts Information Important: The trucks affected by this bulletin that have rear air conditioning were built with two different length condensers. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering one of the tubes listed below for vehicles with rear air conditioning. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 06-01-38-002 > Mar > 06 > A/C - Hiss Noise From Instrument Panel > Page 2857 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 06-01-38-002 > Mar > 06 > A/C - Hiss Noise From Instrument Panel Hose/Line HVAC: All Technical Service Bulletins A/C - Hiss Noise From Instrument Panel Bulletin No.: 06-01-38-002 Date: March 17, 2006 TECHNICAL Subject: A/C System Refrigerant Hiss Noise (Replace Liquid Line) Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, T, Z, B, U, N, G - RPOs LU3, LR4, LM7, L59, L33, LQ4, LQ9, L18) and Air Conditioning (RPOs CJ2, CJ3 and C69) Condition Some customers may comment on a hiss noise coming from the instrument panel. The noise has also been described as sounding like a gurgle or water spattering. The noise occurs when the Air Conditioning (A/C) compressor engages and may continue for 5 to 10 seconds after the compressor disengages or the A/C system is turned off. The noise is most noticeable when the vehicle is at idle or is being driven at low speeds. The noise is undetectable after about one minute when the A/C system has been turned off or the vehicle has been turned off. Cause This condition may be caused by the expanding refrigerant as it passes through the orifice tube. Correction Technicians are to verify that the customer concern is only as described in the condition statement above. If the customer concern is a refrigerant hiss noise, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly, and all other possible sources of this noise are eliminated, then technicians are to replace the A/C liquid line. Use the proper part number as described in the parts information box below. Verify that the noise has been eliminated and that the A/C system operates normally. Parts Information Important: The trucks affected by this bulletin that have rear air conditioning were built with two different length condensers. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering one of the tubes listed below for vehicles with rear air conditioning. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 06-01-38-002 > Mar > 06 > A/C - Hiss Noise From Instrument Panel > Page 2863 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement Hose/Line HVAC: Service and Repair Discharge Hose Replacement DISCHARGE HOSE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. 3. Remove the discharge hose (1) from the A/C compressor. 4. Remove the upper radiator baffle. 5. Remove the discharge hose nut from the condenser. 6. Remove the discharge hose from the condenser. 7. Disconnect the electrical connector from the A/C recirculation switch. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2866 1. Install the discharge hose (1) to the vehicle. 2. Connect the electrical connector to the A/C recirculation switch. 3. Install the discharge hose to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the discharge hose nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Install the upper air baffle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2867 6. Install the discharge hose (1) to the A/C compressor using new sealing washers. 7. Install the discharge hose mounting bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2868 Hose/Line HVAC: Service and Repair Suction Hose Replacement (W/ Denso) SUCTION HOSE REPLACEMENT (W/DENSO) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the suction hose mounting bolt from the A/C compressor. 3. Remove the suction hose (2) from the A/C compressor. 4. Remove the suction hose nut from the accumulator. 5. Remove the suction hose from the accumulator. 6. Remove the suction hose assembly from the vehicle. 7. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE 1. Install the suction hose to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2869 2. Install the suction hose to the accumulator using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 4. Install the suction hose (2) to the compressor using new sealing washers. 5. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fittings of the component using the J 39400-A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2870 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (Without RPO Code HP2) EVAPORATOR TUBE REPLACEMENT (W/O HP2) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Remove the right park/turn signal lamp. 5. Remove the grille from the vehicle. 6. Remove the evaporator tube nut from the condenser. 7. Remove the evaporator tube from the condenser. 8. Remove the evaporator tube from the vehicle. 9. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE 1. Install the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 2871 2. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 3. Install the grille to the vehicle. 4. Install the right park/turn signal lamp. 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings of the components using the J 39400-A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures Technical Service Bulletin # 05086A Date: 051116 Recall - Power Steering Hose Fractures Product Safety - Power Steering Hose Fracture # 05086A - (Nov 16, 2005) Models: 2006 BUICK RAINIER 2006 CADILLAC ESCALADE 2005 CHEVROLET CORVETTE, SILVERADO 2006 CHEVROLET CORVETTE, EXPRESS, SILVERADO, TAHOE, TRAILBLAZER, TRAILBLAZER EXT 2005 GMC SIERRA 2006 GMC ENVOY, ENVOY XL, SAVANA, SIERRA, YUKON 2006 HUMMER H2 ALSO USED AS A SERVICE PART (18 PART NUMBERS INVOLVED) This bulletin is being revised to address hoses used to service 1991-2006 vehicles. Dealers who ordered these hoses for service are identified in the attachment contained in the Administrative Message (U.S.) or Dealer Communication (Canada). Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles. Some of these vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with hydro-boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. Note: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991-2006 vehicles. Correction Dealers are to inspect the power steering hose(s) for two suspect date codes and replace them if required. Dealers who have ordered the involved hoses for service (see listing in Administrative Message) are to search their part sales records to determine the name and address of the purchaser(s). If the purchaser is the owner of the vehicle, dealers are to send the owner a copy of the appropriate letter shown in this bulletin requesting them to bring their vehicle in for repair. If the purchaser is a body shop, independent repair shop, etc., dealers are to send the shop a copy of the appropriate letter shown in this bulletin requesting that they provide the customer's name, address, and telephone number so the dealer can send the owner a copy of the letter. Vehicles Involved Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2880 Involved are certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991 - 2006 vehicles. Affected dealers have already been issued a Special Return Bulletin to return any shelf stock, refer to Administrative Message VSU20050801 - GMP05 -157. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Dealers that have ordered involved hoses for service will also be listed in the report contained in the Administrative Message. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete vehicle identification number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Less than 10% of the involved vehicles will require hose replacement. If parts are required, order the appropriate hose(s) from General Motors Service Parts Operations (GMSPO). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Claim Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2881 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2882 Submit a Product Recall claim with the information shown. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). For vehicles with the recalled component installed on their vehicles outside of warranty, dealers are to notify customers of this recall using a copy of the letter shown in this bulletin. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possession The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2883 Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Following this customer letter is another letter for customers identified through dealer search retype this letter and insert the appropriate information. Disclaimer Service Procedure Inspection Procedure 1. Inspect and record the power steering pressure line for the date code as shown above. The date code is printed on the hose and is repeated approximately every 6 inches (150 mm). Depending on the vehicle configuration, there may be one or two hoses to inspect. Vehicles equipped with the hydro-boost system will have two hoses while others will only have one hose. Removal of conduit may be necessary in order to inspect the date code. 2. Rainier/TrailBlazer/TrailBlazer EXT/Envoy/Envoy XL with 4.2L Engine Power Steering Pressure Hose (1). This pressure line has two hose sections and both must be inspected. Vehicle may need to be lifted to inspect both. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2884 3. Express/Savana Steering Pump to Hydro-Boost Pressure Line (2). 4. Express/Savana Hydro-Boost to Steering Gear Pressure Line (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2885 5. Silverado/Tahoe/Sierra/Yukon/Escalade Non Hydro-Boost Pressure Line (3). 6. Silverado/Tahoe/Sierra/Yukon/Escalade Power Steering Pump to Hydro-Boost Pressure Line (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2886 7. Silverado/Tahoe/Sierra/Yukon/Escalade Hydro-Boost to Steering Gear Pressure Line (1). 8. Hummer H2 Power Steering Pump to Hydro-Boost Pressure Line. 9. Hummer H2 Hydro-Boost to Steering Gear Pressure Line. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2887 10. Corvette Power Steering Pressure Hose (2). The vehicle will need to be lifted on a hoist for inspection. Removal of the power steering cooler bolts will give increased access to the pressure hose. 11. Compare the date code on the hose(s) to the suspect date codes shown. - If the date code is one of the codes listed, the hose(s) must be replaced. Proceed to the Hose Replacement Procedure. - If the date code is not one of the codes shown, then replace the conduit if applicable and no further action is required. Hose Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2888 If the inspection reveals that the hose needs to be replaced, follow the instructions in SI. Shown are the SI document numbers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2889 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2890 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2891 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2892 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2893 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls for Power Steering Line/Hose: > NHTSA05V455000 > Oct > 05 > Recall 05V455000: Power Steering Hose Fracturing Power Steering Line/Hose: Recalls Recall 05V455000: Power Steering Hose Fracturing MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2006 Cadillac/Escalade 2006 Chevrolet/Corvette 2005-2006 Chevrolet/Express 2006 Chevrolet/Silverado 2005-2006 Chevrolet/Tahoe 2006 Chevrolet/Trailblazer 2006 Chevrolet/Trailblazer EXT 2006 GMC/Envoy 2006 GMC/Envoy XL 2006 GMC/Savana 2006 GMC/Sierra 2005-2006 GMC/Yukon 2006 Hummer/H2 2006 Isuzu/Ascender 2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V455000 MFG'S REPORT DATE: October 04, 2005 COMPONENT: Steering: Hydraulic Power Assist: Hose, Piping, and Connections POTENTIAL NUMBER OF UNITS AFFECTED: 123592 SUMMARY: Certain passenger vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. CONSEQUENCE: If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with Hydro-Boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. REMEDY: Dealers will inspect the power steering hose(s) for two suspect date codes and replace them if required. The recall will begin on October 14, 2005. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Buick at 1-866-608-8080, Cadillac at 1-866-982-2339, Isuzu at 1-800-255-6727, or HUMMER at 1-800-732-5493. NOTES: GM recall No. 05086. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures Technical Service Bulletin # 05086A Date: 051116 Recall - Power Steering Hose Fractures Product Safety - Power Steering Hose Fracture # 05086A - (Nov 16, 2005) Models: 2006 BUICK RAINIER 2006 CADILLAC ESCALADE 2005 CHEVROLET CORVETTE, SILVERADO 2006 CHEVROLET CORVETTE, EXPRESS, SILVERADO, TAHOE, TRAILBLAZER, TRAILBLAZER EXT 2005 GMC SIERRA 2006 GMC ENVOY, ENVOY XL, SAVANA, SIERRA, YUKON 2006 HUMMER H2 ALSO USED AS A SERVICE PART (18 PART NUMBERS INVOLVED) This bulletin is being revised to address hoses used to service 1991-2006 vehicles. Dealers who ordered these hoses for service are identified in the attachment contained in the Administrative Message (U.S.) or Dealer Communication (Canada). Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles. Some of these vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with hydro-boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. Note: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991-2006 vehicles. Correction Dealers are to inspect the power steering hose(s) for two suspect date codes and replace them if required. Dealers who have ordered the involved hoses for service (see listing in Administrative Message) are to search their part sales records to determine the name and address of the purchaser(s). If the purchaser is the owner of the vehicle, dealers are to send the owner a copy of the appropriate letter shown in this bulletin requesting them to bring their vehicle in for repair. If the purchaser is a body shop, independent repair shop, etc., dealers are to send the shop a copy of the appropriate letter shown in this bulletin requesting that they provide the customer's name, address, and telephone number so the dealer can send the owner a copy of the letter. Vehicles Involved Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2903 Involved are certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991 - 2006 vehicles. Affected dealers have already been issued a Special Return Bulletin to return any shelf stock, refer to Administrative Message VSU20050801 - GMP05 -157. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Dealers that have ordered involved hoses for service will also be listed in the report contained in the Administrative Message. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete vehicle identification number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Less than 10% of the involved vehicles will require hose replacement. If parts are required, order the appropriate hose(s) from General Motors Service Parts Operations (GMSPO). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Claim Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2904 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2905 Submit a Product Recall claim with the information shown. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). For vehicles with the recalled component installed on their vehicles outside of warranty, dealers are to notify customers of this recall using a copy of the letter shown in this bulletin. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possession The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2906 Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Following this customer letter is another letter for customers identified through dealer search retype this letter and insert the appropriate information. Disclaimer Service Procedure Inspection Procedure 1. Inspect and record the power steering pressure line for the date code as shown above. The date code is printed on the hose and is repeated approximately every 6 inches (150 mm). Depending on the vehicle configuration, there may be one or two hoses to inspect. Vehicles equipped with the hydro-boost system will have two hoses while others will only have one hose. Removal of conduit may be necessary in order to inspect the date code. 2. Rainier/TrailBlazer/TrailBlazer EXT/Envoy/Envoy XL with 4.2L Engine Power Steering Pressure Hose (1). This pressure line has two hose sections and both must be inspected. Vehicle may need to be lifted to inspect both. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2907 3. Express/Savana Steering Pump to Hydro-Boost Pressure Line (2). 4. Express/Savana Hydro-Boost to Steering Gear Pressure Line (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2908 5. Silverado/Tahoe/Sierra/Yukon/Escalade Non Hydro-Boost Pressure Line (3). 6. Silverado/Tahoe/Sierra/Yukon/Escalade Power Steering Pump to Hydro-Boost Pressure Line (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2909 7. Silverado/Tahoe/Sierra/Yukon/Escalade Hydro-Boost to Steering Gear Pressure Line (1). 8. Hummer H2 Power Steering Pump to Hydro-Boost Pressure Line. 9. Hummer H2 Hydro-Boost to Steering Gear Pressure Line. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2910 10. Corvette Power Steering Pressure Hose (2). The vehicle will need to be lifted on a hoist for inspection. Removal of the power steering cooler bolts will give increased access to the pressure hose. 11. Compare the date code on the hose(s) to the suspect date codes shown. - If the date code is one of the codes listed, the hose(s) must be replaced. Proceed to the Hose Replacement Procedure. - If the date code is not one of the codes shown, then replace the conduit if applicable and no further action is required. Hose Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2911 If the inspection reveals that the hose needs to be replaced, follow the instructions in SI. Shown are the SI document numbers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2912 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2913 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2914 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2915 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 2916 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > NHTSA05V455000 > Oct > 05 > Recall 05V455000: Power Steering Hose Fracturing Power Steering Line/Hose: All Technical Service Bulletins Recall 05V455000: Power Steering Hose Fracturing MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2006 Cadillac/Escalade 2006 Chevrolet/Corvette 2005-2006 Chevrolet/Express 2006 Chevrolet/Silverado 2005-2006 Chevrolet/Tahoe 2006 Chevrolet/Trailblazer 2006 Chevrolet/Trailblazer EXT 2006 GMC/Envoy 2006 GMC/Envoy XL 2006 GMC/Savana 2006 GMC/Sierra 2005-2006 GMC/Yukon 2006 Hummer/H2 2006 Isuzu/Ascender 2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V455000 MFG'S REPORT DATE: October 04, 2005 COMPONENT: Steering: Hydraulic Power Assist: Hose, Piping, and Connections POTENTIAL NUMBER OF UNITS AFFECTED: 123592 SUMMARY: Certain passenger vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. CONSEQUENCE: If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with Hydro-Boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. REMEDY: Dealers will inspect the power steering hose(s) for two suspect date codes and replace them if required. The recall will begin on October 14, 2005. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Buick at 1-866-608-8080, Cadillac at 1-866-982-2339, Isuzu at 1-800-255-6727, or HUMMER at 1-800-732-5493. NOTES: GM recall No. 05086. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Removal Procedure 1. Remove the front grille. 2. Place a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Siphon the fluid from the reservoir to prevent excess spillage. 4. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear (2). 5. Remove the clamp retaining power steering cooler outlet hose (5) to the power steering pump (1). 6. Remove the bolts (2) retaining the power steering cooler from the radiator support. 7. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2923 2. Install the power steering cooler outlet hose (3) to the power steering pump (2). 3. Install the retaining clamp. 4. Install the power steering inlet hose (5) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2924 Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Remove the front grille. 2. Remove the clamp retaining the power steering outlet hose (3) from the power steering gear (4). Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the clamp retaining the power steering inlet hose from the power steering pump (5). 4. Remove the bolts (2) retaining the power steering cooler from the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2925 2. Connect the power steering outlet hose (3) to the power steering gear (4). 3. Install the retaining clamp. 4. Connect the power steering inlet hose to the power steering pump. 5. Install the retaining clamp. 6. Bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2926 Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Removal Procedure 1. Remove the front grille. 2. Remove the power steering outlet hose (4) from the power steering gear (3). Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering inlet hose from the power steering pump (1). 4. Remove the bolts (2) retaining the cooler to the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2927 2. Connect the power steering inlet hose to the power steering pump (5). Install the retaining clamp. 3. Connect the power steering outlet hose (4) to the power steering gear (3). Install the retaining clamp. 4. Bleed the power steering system. 5. Inspect all the hose connections for leaks. 6. Install the front grille. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2928 Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 3. Place a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 4. Siphon the fluid from the reservoir to prevent excess spillage. 5. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear. 6. Remove the clamp retaining power steering cooler outlet hose (2) to the power steering pump (1). 7. Remove the bolts (2) retaining the power steering cooler from the radiator support. 8. Remove the power steering cooler from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2929 1. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the power steering cooler outlet hose (2) to the power steering pump (1). 3. Install the retaining clamp. 4. Install the power steering inlet hose (3) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. 9. Connect the energy storage box after servicing the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2930 Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Removal Procedure 1. Remove the front grille. 2. Place a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Siphon the fluid from the reservoir to prevent excess spillage. 4. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear (2). 5. Remove the clamp retaining power steering cooler outlet hose (5) to the power steering pump (1). 6. Remove the bolts (2) retaining the power steering cooler from the radiator support. 7. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2931 2. Install the power steering cooler outlet hose (3) to the power steering pump (2). 3. Install the retaining clamp. 4. Install the power steering inlet hose (5) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Remove the front grille. 2. Remove the clamp retaining the power steering outlet hose (3) from the power steering gear (4). Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the clamp retaining the power steering inlet hose from the power steering pump (5). 4. Remove the bolts (2) retaining the power steering cooler from the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2932 1. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the power steering outlet hose (3) to the power steering gear (4). 3. Install the retaining clamp. 4. Connect the power steering inlet hose to the power steering pump. 5. Install the retaining clamp. 6. Bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Removal Procedure 1. Remove the front grille. 2. Remove the power steering outlet hose (4) from the power steering gear (3). Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering inlet hose from the power steering pump (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2933 4. Remove the bolts (2) retaining the cooler to the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the power steering inlet hose to the power steering pump (5). Install the retaining clamp. 3. Connect the power steering outlet hose (4) to the power steering gear (3). Install the retaining clamp. 4. Bleed the power steering system. 5. Inspect all the hose connections for leaks. 6. Install the front grille. Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2934 3. Place a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 4. Siphon the fluid from the reservoir to prevent excess spillage. 5. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear. 6. Remove the clamp retaining power steering cooler outlet hose (2) to the power steering pump (1). 7. Remove the bolts (2) retaining the power steering cooler from the radiator support. 8. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2935 2. Install the power steering cooler outlet hose (2) to the power steering pump (1). 3. Install the retaining clamp. 4. Install the power steering inlet hose (3) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. 7. Inspect all the hose connections for leaks. 8. Install the front grille. 9. Connect the energy storage box after servicing the vehicle. Power Steering Hose Assembly Replacement (Non Rack and Pinion) Power Steering Hose Assembly Replacement (Non Rack and Pinion) Removal Procedure 1. Disconnect the energy storage box before serving the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2936 6. Remove the power steering gear inlet hose (4) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2937 1. Install the gear inlet hose to the gear (4). Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. 2. Install the booster inlet hose to the pump. Important: Ensure that the hose contacts the power steering pump as shown. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2938 3. Install the booster outlet hose to the power steering pump nipple (5) and retaining clamp. 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. 9. Connect the energy storage box after servicing the vehicle. Power Steering Hose Assembly Replacement (Rack and Pinion Power Steering Hose Assembly Replacement (Rack and Pinion) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2939 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. 6. Remove the power steering gear inlet hose (5) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose (5) from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2940 1. Install the booster inlet hose to the pump. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. Important: Ensure that the hose contacts the power steering pump as shown. 2. Install the gear inlet hose to the gear (5). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2941 3. Install the booster outlet hose to the power steering pump nipple and retaining clamp (2). 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. 9. Connect the energy storage box before after servicing the vehicle. Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2942 1. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Route the hose in the same position the hose occupied prior to removal. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only. 3. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting 2. Remove the engine protection shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2943 3. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Route the hose in the same position the hose occupied prior to removal. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only. 3. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2944 1. Remove the power steering inlet hose (2) from the power steering pump (1). 2. Remove the power steering inlet hose (2) from the power steering gear (3). Installation Procedure 1. Connect the power steering inlet hose (2) to the power steering gear (3). 2. Connect the power steering inlet hose (2) to the power steering pump (1). ^ Tighten the hose connections to 28 Nm (20 ft. lbs.) Notice: Refer to Fastener Notice in Service Precautions. 3. Bleed the power steering system. 4. Inspect all the hose connections for leaks. Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Removal Procedure 1. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1). Remove the power steering gear outlet hose from the power steering pump. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2945 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure 1. Route the hose in the same position the hose occupied prior to removal. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 2. Install the power steering gear outlet hose (3) to the power steering pump (1). Position the clamp at the end of the hose. 3. Install the power steering gear outlet hose to the power steering gear. ^ Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering outlet hose (4) from the power steering gear (3). 2. Remove the power steering outlet hose (4) from the power steering cooler (5). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2946 1. Connect the power steering outlet hose (4) to the power steering cooler (5). 2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only. 3. Connect the power steering outlet hose (2) to the power steering pump (1). ^ Tighten both hose connections to 28 Nm (20 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Bleed the power steering system. 5. Inspect all the hose connections for leaks. Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2947 1. Route the hose in the same position the hose occupied prior to removal. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only. 3. Install the brake booster inlet hose to the power steering pump. ^ Tighten the brake booster inlet hose fittings to 28 Nm (20 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2948 1. Route the hose in the same position the hose occupied prior to removal. Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 2. Install the brake booster outlet hose (1) to the brake booster (2). Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4). Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. (Non Rack and Pinion) Power Steering Hose Assembly Replacement (Non Rack and Pinion) Removal Procedure 1. Disconnect the energy storage box before serving the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2949 6. Remove the power steering gear inlet hose (4) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2950 1. Install the gear inlet hose to the gear (4). Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. 2. Install the booster inlet hose to the pump. Important: Ensure that the hose contacts the power steering pump as shown. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2951 3. Install the booster outlet hose to the power steering pump nipple (5) and retaining clamp. 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box after servicing the vehicle. (Rack and Pinion) Power Steering Hose Assembly Replacement (Rack and Pinion) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2952 Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. 6. Remove the power steering gear inlet hose (5) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose (5) from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2953 Installation Procedure 1. Install the booster inlet hose to the pump. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. Important: Ensure that the hose contacts the power steering pump as shown. 2. Install the gear inlet hose to the gear (5). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) > Page 2954 3. Install the booster outlet hose to the power steering pump nipple and retaining clamp (2). 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box before after servicing the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet hose. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator inlet hose clips. 7. Reposition the inlet hose clamp at the radiator. 8. Remove the inlet hose clip from the fan shroud. 9. Remove the inlet hose (1) from the radiator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2959 10. Reposition the inlet hose clamp at the water pump. 11. Remove the inlet hose from the water pump. Installation Procedure 1. Install the inlet hose to the water pump. 2. Position the inlet hose clamp at the water pump. 3. Install the inlet hose (1) to the radiator. 4. Position the inlet hose clamp at the radiator. 5. Install the inlet hose clip to the fan shroud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2960 6. Install the radiator vent inlet hose to the radiator inlet hose clips. 7. If necessary, install the engine sight shield. 8. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 9. Install the radiator inlet hose clip to the outlet duct. 10. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Tighten the clamps to 4 Nm (35 inch lbs.). 11. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2961 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the outlet hose clamp at the water pump. 6. Remove the outlet hose from the water pump. 7. Reposition the outlet hose clamp at the radiator. 8. Remove the outlet hose (6) from the radiator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2962 1. Install the outlet hose (6) to the radiator. 2. Position the outlet hose clamp at the radiator. 3. Install the outlet hose to the water pump. 4. Position the outlet hose clamp at the water pump. 5. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. 7. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Tighten the clamps to 4 Nm (35 inch lbs.). 8. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not provided by the vehicle manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 2968 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Information not provided by the vehicle manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 2973 Clutch Fluid: Fluid Type Specifications HYDRAULIC CLUTCH FLUID WITH 5-SPEED TRANSMISSION Hydraulic Clutch Fluid (GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. WITH 6-SPEED TRANSMISSION Hydraulic Clutch Fluid. Use only GM Part No. U.S. 88958860, in Canada 88901244, Super DOT-4 brake fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2978 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2979 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2980 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2981 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM CAPACITY AUTOMATIC WITH FRONT A/C .......................................................................................................................................... 15.2 quarts (14.4 liters) With Engine Driven Cooling Fan AUTOMATIC WITH FRONT A/C ......................................................................................................................................... 16.8 quarts (15.9 liters) With Electric Cooling Fan NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2984 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Differential Fluid - M/T: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Fluid - M/T: > 09-04-19-002A > Feb > 11 > Drivetrain Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Fluid - Transfer Case: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Fluid - Transfer Case: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 3015 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 3016 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 3017 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4L60-E Pan Removal ........................................................................................... .......................................................................................................... 4.7L (5.0 Qt) Overhaul .............. .............................................................................................................................................................. ............................ 10.6L (11.0 Qt) 4L80-E Overhaul ........................................................................... ............................................................................................................................. 12.8L (13.5 Qt) Pan Removal .............................................................................................................................................. ....................................................... 7.3L (7.7 Qt) Allison Overhaul ..................................................... ................................................................................................................................................... 12.0L (12.7 Qt) Fluid and Filter Change ........................................................................................................ ............................................................................. 7.0L (7.4 Qt) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3020 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 4L60-E/4L65-E Transmission Fluid Checking Procedure Fluid - A/T: Testing and Inspection 4L60-E/4L65-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 4L60-E/4L65-E Transmission Fluid Checking Procedure > Page 3023 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82-93°C (180-200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about 3 seconds in each range, ending in PARK. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 4L60-E/4L65-E Transmission Fluid Checking Procedure > Page 3024 Fluid - A/T: Testing and Inspection 4L80-E/4L85-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 4L60-E/4L65-E Transmission Fluid Checking Procedure > Page 3025 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82-93°C (180-200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about three seconds in each range, ending in Park. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E Fluid - A/T: Service and Repair 4L60-E/4L65-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3028 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3029 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82-93°C (180-200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about 3 seconds in each range, ending in PARK. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3030 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3031 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. 4. Install the oil pan and NEW gasket. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Refer to Transmission Fluid Checking Procedure and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3032 Fluid - A/T: Service and Repair 4L80-E/4L85-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3033 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3034 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82-93°C (180-200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about three seconds in each range, ending in Park. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3035 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3036 Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3037 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3038 Fluid - A/T: Service and Repair Fluid Checking Procedure FLUID CHECKING PROCEDURE WITHOUT ALLISON TRANSMISSION WHEN TO CHECK AND CHANGE A good time to check the automatic transaxle fluid level is when the engine oil is changed. Change the fluid and filter at the intervals listed in the Maintenance schedule, and be sure to use the proper transaxle fluid. HOW TO CHECK Because this operation can be a little difficult, you may choose to have this done at the dealership service department. If you do it yourself, be sure to follow all the instructions here, or you could get a false reading on the dipstick. NOTICE: Too much or too little fluid can damage the transaxle. Too much can mean that some of the fluid could come out and fall on hot engine or exhaust system parts, starting a fire. Too little fluid could cause the transaxle to overheat. Be sure to get an accurate reading if you check the transaxle fluid. Wait at least 30 minutes before checking the transaxle fluid level if you have been driving: ^ When outside temperatures are above 90°F (32°C). ^ At high speed for quite a while. ^ In heavy traffic - especially in hot weather. ^ While pulling a trailer. To get the right reading, the fluid should be at normal operating temperature, which is 180°F to 200°F (82°C to 93°C). Get the vehicle warmed up by driving about 15 miles (24 km) when outside temperatures are above 50°F (10°C). If it is colder than 50°F (10°C), you may have to drive longer. CHECKING THE FLUID LEVEL Prepare the vehicle as follows: 1. Park the vehicle on a level place. Keep the engine running. 2. With the parking brake applied, place the shift lever in PARK (P). 3. With your foot on the brake pedal, move the shift lever through each gear, pausing for about three seconds in each gear. Then, position the shift lever in PARK (P). 4. Let the engine run at idle for three to five minutes. 5. Then, without shutting off the engine, follow these steps: ^ The automatic transaxle fluid dipstick handle is the black loop located toward the rear of the engine. ^ Pull out the dipstick and wipe it with a clean rag or paper towel. ^ Push it back in all the way, wait three seconds, and pull it back out again. ^ Check both sides of the dipstick, and read the lower level. The fluid level must be in the crosshatched area. ^ If the fluid level is in the acceptable range, push the dipstick back in all the way. CONSISTENCY OF READINGS Always check the fluid level at least twice using the procedure described previously. Consistency (repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist, check the transmission breather hose to be sure it is clean and unclogged. HOW TO ADD FLUID If the fluid level is low, add only enough of the proper fluid to bring the level into the crosshatched area on the dipstick. 1. Pull out the dipstick. 2. Using a long-neck funnel, add enough fluid at the dipstick hole to bring it to the proper level. It does not take much fluid, generally less than one pint (0.5 liters). Do not overfill. NOTICE: Use of automatic transaxle fluid labeled other than DEXRON-III may damage your vehicle, and the damages may not be covered by your warranty. Always use DEXRON-III labeled automatic transaxle fluid. 3. After adding fluid, recheck the fluid level as described under "How to Check," earlier in this article. When the correct fluid level is obtained, push the dipstick back in all the way. WITH ALLISON TRANSMISSION NOTE: Be sure to follow all the instructions here, or you could get a false reading on the dipstick. NOTICE: Too much or too little fluid can damage your transmission. Too much can mean that some of the fluid could come out and fall on hot Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 3039 engine part or exhaust system parts, starting a fire. Too little fluid could cause the transmission to overheat. Be sure to get an accurate reading if you check your transmission fluid. Wait at least 30 minutes before checking the transmission fluid level if you have been driving: * When outside temperatures are above 90°F (32°C). * At high speed for quite a while. * In heavy traffic -- especially in hot weather. * While pulling a trailer. CHECKING THE FLUID LEVEL Prepare your vehicle as follows: 1. Park your vehicle on a level place. Keep the engine running. 2. With the parking brake applied, place the shift lever in PARK (P). 3. With your foot on the brake pedal, run the engine for at least once minute and shift to DRIVE (D). Then shift to NEUTRAL (N) and then REVERSE (R) to fill the hydraulic system. Then, position the shift lever in PARK (P). 4. Allow the engine to run at idle (500-800 rpm). Slowly release the brake pedal. 5. Then, without shutting off the engine, follow these steps: COLD CHECK PROCEDURE The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made. The fluid level rises as fluid temperature increases. Do not fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures. 1. Pull out the dipstick and wipe it with a clean rag or paper towel. 2. Push it back in all the way, wait three seconds and then pull it back out again. 3. Check the fluid level reading. Repeat the check procedure to verify the reading. 4. If the fluid level is within the COLD CHECK band, the transmission may be operated until the fluid is hot enough to perform a hot check. If the fluid level is not within the COLD CHECK band, add or drain fluid as necessary to bring the level into the middle of the COLD CHECK band. 5. Perform a hot check at the first opportunity after the normal operating temperature of 160°F (71°C) to 200°F (93°C) is reached. 6. If the fluid level is in the acceptable range, push the dipstick back in all the way. HOT CHECK PROCEDURE The fluid must be hot to ensure an accurate check. The fluid level rises as the temperature increases. 1. Operate the transmission in DRIVE (D) range until the normal operating temperature of 160°F (71°C) to 200°F (93°C) is reached. 2. Pull out the dipstick and wipe it with a clean rag or paper towel. 3. Push it back in all the way, wait three seconds and then pull it back out again. Repeat the check procedure to verify the reading. 4. Safe operating level is within the HOT RUN band on the dipstick. The width of the HOT RUN band represents approximately 1.06 quart (1.0 liter) of fluid at normal operating temperature. 5. If the fluid level is not within the HOT RUN band, add or drain fluid as necessary to bring the fluid level to within the HOT RUN band. 6. If the fluid level is in the acceptable range, push the dipstick back in all the way. CONSISTENCY OF READINGS Always check the fluid level at least twice using the procedures described previously. Consistency (repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist, check the transmission breather to be sure it is clean and unclogged. If readings are still inconsistent, contact your dealer. HOW TO ADD AUTOMATIC TRANSMISSION FLUID Refer to the Maintenance Schedule to determine what kind of transmission fluid to use. Add fluid only after checking the transmission fluid while it is hot. A cold check is used only as a reference. If the fluid level is low, add only enough of the proper fluid to bring the level up to the HOT area for a hot check. It does not take much fluid, generally less than one pint (0.5 liters). Do not overfill. NOTICE: Use of the incorrect automatic transmission fluid may damage your vehicle, and the damages may not be covered by your warranty. Always use the automatic transmission fluid. After adding fluid, recheck the fluid level as described under "How to Check Automatic Transmission Fluid," earlier in this section. When the correct fluid level is obtained, push the dipstick back in all the way. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid NV3500 ................................................................................................................ ............................................................................................. 2.0L (2.2 Qt) NV4500 ............................ .............................................................................................................................................................. ................... 3.7L (4.0 Qt) 6 Speed (ZF) (RPO ML6) ........................................................................... ...................................................................................................... 6.0L (6.3 Qt) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 3044 Fluid - M/T: Fluid Type Specifications Manual Transmission 5-Speed with Low Gear - RPO MW3 GM Goodwrench Synthetic Manual Transmission Fluid (GM Part No. U.S. 12346190, in Canada 10953477) or equivalent SAE 75W-85 GL-4 gear oil. 5-Speed without Low Gear - RPO MG5 Synchromesh Transmission Fluid (GM Part No. U.S. 12345349, in Canada 10953465). 6-Speed Castrol TransSynd Synthetic Transmission Fluid approved to Allison Transmission specification TES-295 (GM Part No. U.S. 12378515, in Canada 88900701). RPO MG5 - Transmission Manual 5-Speed, Getrag, 84mm, 4.00 1st, O/D RPO MW3 Transmission Manual 5-Speed, NVG, 109mm, 5.61 1st, O/D Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 Fluid - M/T: Service and Repair NV 3500 Transmission Fluid Replacement ^ Tools Required J 36511 Oil Fill/Drain Plug Hex Bit (17 MM) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 3047 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. 2. Notice: Refer to Fastener Notice in Service Precautions. Using J 36511 install the oil drain plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 3048 5. Using J 36511 install the oil fill plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 3049 Fluid - M/T: Service and Repair NV 4500 Control Lever and/or Boot Replacement Removal Procedure 1. Important: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. Remove the control lever. 2. Remove the control lever boot retainer plastic retainers, if necessary. 3. Remove the control lever boot retainer, if necessary. 4. Remove the control lever boot screws, if necessary. 5. Remove the control lever boot, if necessary. 6. Remove the control lever insulator, if necessary. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 3050 1. Install the control lever insulator, if removed. 2. Install the control lever boot to the control lever, if removed. 3. Install the control lever. 4. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 5. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. 6. Notice: Refer to Fastener Notice in Service Precautions. Hold the control lever and tighten the shift lever assembly nut against the control lever. ^ Tighten the nut to 37 Nm (27 ft. lbs.). 7. Seat the control lever boot to the floor. 8. Install the control lever boot screws, if removed. ^ Tighten the screws to 1.6 Nm (14 inch lbs.). 9. Install the control lever boot retainer, if removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 3051 Fluid - M/T: Service and Repair ZF S6-650 Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing and plugs. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the oil drain and fill plugs. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 3. Fill the transmission to just below the bottom of the fill plug hole. 4. Install the oil fill plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 3056 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Information not provided by manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3059 Fluid - Differential: Fluid Type Specifications DIFFERENTIAL FLUID Front Axle - Four-Wheel Drive SAE 80W-90 Axle Lubricant (GM Part No. U.S. 1052271, in Canada 10950849). Front Axle - All-Wheel Drive SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 12378261, in Canada 10953455) meeting GM Specification 9986115. Rear Axle SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 12378261, in Canada 10953455) meeting GM Specification 9986115. Rear Axle - Steerable Synthetic Axle Lubricant; use only GM Part No. U.S. 12378557, in Canada 88901362.Do not add friction modifier. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant Fluid - Differential: Service and Repair When to Check Lubricant When to Check Lubricant It is not necessary to regularly check front or rear axle fluid unless you suspect there is a leak or you hear an unusual noise. A fluid loss could indicate a problem. Have it inspected and repaired. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 3062 Fluid - Differential: Service and Repair Front Drive Axle Lubricant Level Inspection Lubricant Level Inspection - Front Drive Axle 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. ^ For the 8.25 inch axle, the oil level should be between 12-16 mm (0.50-0.625 inch) below the fill plug opening. ^ For the 9.25 inch axle, the oil level should be between 0-6 mm (0-0.25 inch) below the fill plug opening. 7. If the level is low, add oil until the level is between 12-16 mm (0.50-0.625 inch) for the 8.25 inch axle or 0-6 mm (0-0.25 inch) for the 9.25 inch axle. Use the correct fluid. 8. Install the fill plug. ^ Tighten the plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Lower the vehicle. Lubricant Replacement Lubricant Replacement - Front Drive Axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the front differential carrier shield, if equipped. 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 3063 Installation Procedure 1. Install the drain plug. ^ Tighten the drain plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. 3. Install the fill plug. ^ Tighten the fill plug to 33 Nm (24 ft. lbs.). 4. Install the front differential carrier shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 3064 Fluid - Differential: Service and Repair Rear Differential Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". 7. Insert the pipe cleaner into the fill plug opening with the stem facing down. 8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The distance between the bend and the lubricant level should be 15 - 40 mm (0.6 - 1.6 inch). 9. If the measurement is greater than 40 mm (1.6 inch), add lubricant until the level is between 15 40 mm (0.6 - 1.6 inch) from the bottom edge of the fill plug hole. Use the proper fluid. 10. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Service Precautions. 11. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (9.5/9.5LD, 10.5 Inch Axles) Lubricant Level Inspection - Rear Drive Axle (9.5/9.5LD, 10.5 Inch Axles) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 3065 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Service Precautions. 9. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (9.75 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (9.75 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0 - 4 mm (0 - 0.16 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). Notice: Refer to Service Precautions. 9. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17 - 21 mm (0.6 - 0.8 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is between 17 - 21 mm (0.6 - 0.8 inch) below the fill plug opening. Use the proper fluid. 8. Install the rear axle fill plug and gasket. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 3066 Notice: Refer to Service Precautions. 9. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) Removal Procedure 1. Raise the vehicle. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Carefully remove the rear axle housing cover (2) and drain the lubricant into a suitable container. 5. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. 6. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation is an indication of extreme wear. Installation Procedure 1. Install a new gasket and the rear axle housing cover (2). 2. Install the new rear axle housing cover bolts (1). ^ Tighten the bolts to 40 Nm (30 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 3067 Notice: Refer to Service Precautions. Important: Do not reuse the rear axle housing cover bolts. 3. Fill the rear axle. Use the proper fluid. 4. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle) Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 3068 1. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 27 Nm (20 ft. lbs.). Notice: Refer to Service Precautions. 2. Fill the rear axle. Use the proper fluid. 3. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 4. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (9.5/9.5LD, 10.5, and 11.5 Inch Axles) Lubricant Replacement - Rear Drive Axle (9.5/9.5LD, 10.5, and 11.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. For the 9.5/9.5LD and the 10.5 inch axles, remove the rear axle fill plug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 3069 3. For the 11.5 inch axle, remove the fill plug. 4. Remove the rear axle drain plug. 5. Drain the lubricant into a suitable container. 6. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 7. Clean the drain plug. Installation Procedure 1. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 33 Nm (24 ft. lbs.). Notice: Refer to Service Precautions. 2. Fill the rear axle. Use the proper fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 3070 3. For the 9.5/9.5LD and the 10.5 inch axles, install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 4. For the 11.5 inch axle, install the seal and the fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case NVG 149 (RPO NP3) ........................................................................................................................... .......................................................... 2.1L (2.22 Qt) NVG 246 (RPO NP8) ........................................ .............................................................................................................................................. Not Specified NVG 261 (RPO NP2) ........................................................................................................... ........................................................................... Not Specified NVG 263 (RPO NPI) ......................... .............................................................................................................................................................. . 1.9L (2.0 Qt) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 3075 Fluid - Transfer Case: Fluid Type Specifications NVG 149-NP3 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 246-NP8 ......................................................................................... Auto-Trak II, transfer case fluid, GM P/N 12378508 (Canadian P/N 10953626) NVG 261-NP2 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 263-NP1 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Important: Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 3078 2. Fill the transfer case to the bottom of the fill plug hole with DEXRON® III, GM P/N 12346143 (Canadian P/N 10952622). 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 3079 Fluid - Transfer Case: Service and Repair NVG 246-NP8 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedures, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Install the drain plug. Tighten Tighten the plug to 20 N.m (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 3080 2. Fill the transfer case to the bottom of the fill plug hole with Auto-Trak II, transfer case fluid, GM P/N 12378-508 (Canadian P/N 10953626). 3. Install the fill plug. Tighten Tighten the plug to 20 N.m (15 lb ft). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 3081 Fluid - Transfer Case: Service and Repair NVG 261-NP2 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following service procedures, use only hand tools in order to remove and install the fill or drain plugs. Always start the plugs by hand in order to prevent cross threading. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: If the drain or fill plug have to be replaced, use only aluminum replacement drain plugs. Steel plugs will react with the magnesium of the transfer case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved transfer case fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 3082 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 3083 Fluid - Transfer Case: Service and Repair NVG 263-NP1 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 3084 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3089 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3090 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 4.7L (5.0 Qt) With Filter Change ............................................ ................................................................................................................................................. 5.7L (6.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3093 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Grade ............................................................... ............................................................................................................................................................ 5W-30 Below -29° C (-20° F) ................................................................................................................................................. 5W-30 synthetic (preferred) , 0W-30 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 3094 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 3095 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Information not provided by the manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 3100 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 3105 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 3106 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge Refrigerant Charge .............................................................................................................................. ............................................................ 0.7 kg (1.6 lb) Refrigerant Charge Utility with Front and Rear A/C ....................................................................................................................................... 1.2 kg (2.7 lb) Refrigerant Charge Suburban with Front and Rear A/C .................................................................................................................................. 1.5 kg (3.0 lb) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 3109 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 3110 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES ACCUMULATOR REPLACEMENT NOTE: Add 60 ml (2 oz) of PAG oil, plus the equal amount of oil drained from the accumulator. COMPRESSOR REPLACEMENT ......................................................................................................................................................... 60 ml (2.0 oz) NOTE:The Denso replacement compressor is precharged with 237 ml (8.0 oz) of PAG oil. CONDENSER REPLACEMENT ............................................................................................................................................................ 30 ml (1.0 oz) EVAPORATOR REPLACEMENT ......................................................................................................................................................... 90 ml (3.0 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount drained. TOTAL SYSTEM PAG OIL CAPACITY ............................................................................................................................................ 210 ml (7.1 oz) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 3117 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL Polyalkylene glycol (PAG) Oil ................................................................................................................ GM P/N 12378526 (Canadian P/N 88900060) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice; When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11 GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. 10. With the ignition OFF, apply the brakes 3 - 5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3122 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3 - 5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3123 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 23. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3124 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Tools Required ^ J29532 Diaphragm Type Brake Pressure Bleeder, or equivalent ^ J35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3 - 5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J29532, or equivalent, to the J35589-A. 8. Charge the J29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3125 tightened. 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J35589-A. 23. Remove the J35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3126 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing HYDRAULIC BRAKE SYSTEM FLUSHING Caution: Brake fluid may irritate eyes and skin. In case of contact, take the following actions: * Eye contact--rinse thoroughly with water. * Skin contact--wash with soap and water. * If ingested--consult a physician immediately. Notice: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: » Fluid separation, indicating two types of fluid are present. A substance other than the recommended brake fluid has been introduced into the brake hydraulic system. - Swirled appearance--Oil-based substance - Layered appearance--Silicone-based substance » Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system. - Cloudy appearance--Moisture - Dark appearance/suspended particles in fluid--Dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 3.1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid. Refer to the procedures indicated. - Master Cylinder Replacement - Front Brake Hose Replacement - Rear Brake Hose Replacement - Front Brake Caliper Replacement - Rear Brake Caliper Replacement - Brake Pressure Modulator Valve Replacement 3.2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3.3. Dry the brake pipes using non-lubricated, filtered air. 3.4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated. - Master Cylinder Replacement - Also perform the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3127 - Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement . - Replace the brake master cylinder reservoir cap diaphragm. - Front Brake Hose Replacement - Rear Brake Hose Replacement - Front Brake Caliper Overhaul or Front Brake Caliper Replacement - Rear Brake Caliper Overhaul or Rear Brake Caliper Replacement - Brake Pressure Modulator Valve Replacement 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3128 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11 (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3133 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both front end sensor connectors (2) located on the frame crossmember (1). IMPORTANT: This vehicle is equipped with two inflatable restraint front end sensors. When performing this procedure be sure to include both front end sensors. 7. Disconnect both front end sensor connectors (2). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the front end sensor connectors (2) to both front end sensors. 3. Install the CPAs to both front end sensor connectors (2). 4. Install the SIR fuse into the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3134 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 6. Disconnect the steering wheel module yellow 4-way connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3135 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) from the instrument panel (I/P) module yellow 4-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 4-way connector (1). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the I/P module yellow 4-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 4-way connector (1). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3136 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both front end sensor connectors (2) located on the frame crossmember (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3137 IMPORTANT: This vehicle is equipped with two inflatable restraint front end sensors. When performing this procedure be sure to include both front end sensors. 7. Disconnect both front end sensor connectors (2). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the front end sensor connectors (2) to both front end sensors. 3. Install the CPAs to both front end sensor connectors (2). 4. Install the SIR fuse into the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 6. Disconnect the steering wheel module yellow 4-way connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3138 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) from the instrument panel (I/P) module yellow 4-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 4-way connector (1). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the I/P module yellow 4-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 4-way connector (1). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3139 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 6 SIR DISABLING AND ENABLING ZONE 6 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the RF door trim panel. 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom right of the door (4). 7. Disconnect the side impact sensor yellow 2-way connector (5). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door (4). 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5). 4. Install the RF door trim panel. 5. Install the SIR fuse to the fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 7 SIR DISABLING AND ENABLING ZONE 7 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3140 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 6. Disconnect the steering wheel module yellow 4-way connector (2). 7. Remove the CPA from the instrument panel (I/P) module yellow 4-way connector (1) located behind the I/P support. 8. Disconnect the I/P module yellow 4-way connector (1). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2). 4. Connect the I/P module yellow 4-way connector (1) located behind the I/P support. 5. Install the CPA to the I/P module yellow 4-way connector (1). 6. Install the SIR fuse to the fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) Fuse: Locations Fuse Block - Underhood - Cooling Fan (10 Series) Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3148 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3149 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3150 Fuse Block - Underhood - Cooling Fan (10 Series) Wire Entry Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3151 Fuse: Locations Fuse Block - Underhood - Secondary Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3152 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3153 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3154 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3155 Fuse Block - Underhood - Secondary Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3156 Fuse Block - Underhood - Secondary Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3157 Fuse: Locations Fuse Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3158 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3159 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3160 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3161 Fuse: Locations Fuse Block - Underhood Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3162 Application Table Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3163 Application Table Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3164 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3165 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3166 Fuse: Locations Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3167 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3168 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3169 Fuse Block - Underhood - Cooling Fan (10 Series) Wire Entry Fuse Block - Underhood - Secondary Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3170 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3171 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3172 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3173 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3174 Fuse Block - Underhood - Secondary Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3175 Fuse Block - Underhood - Secondary Wire Entry Part 2 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3176 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3177 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3178 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3179 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3180 Application Table Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3181 Application Table Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3182 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3183 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3184 Location View Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3185 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3186 Junction Block - I/P Wire Entry Part 2 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) Fuse: Application and ID Fuse Block - Underhood - Cooling Fan (10 Series) Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3189 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3190 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3191 Fuse Block - Underhood - Cooling Fan (10 Series) Wire Entry Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3192 Fuse: Application and ID Fuse Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3193 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3194 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3195 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3196 Fuse: Application and ID Fuse Block - Underhood Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3197 Application Table Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3198 Application Table Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3199 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3200 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3201 Fuse: Application and ID Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3202 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3203 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 3204 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Left I/P Body Control Module (BCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Left I/P > Page 3209 Fuse Block: Locations Fuse Block - Underhood FUSE BLOCK - UNDERHOOD Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Left I/P > Page 3210 Fuse Block - Underhood Label Fuse Block - Underhood Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Left I/P > Page 3211 The Fuse Block - Underhood is located on the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3214 Fuse Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3215 Fuse Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3216 Fuse Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3217 Fuse Block - I/P C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3218 Fuse Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3219 Fuse Block - I/P C4 (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3220 Fuse Block - Underhood Top View Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3221 Fuse Block - Underhood - Cooling Fan (10 Series) Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3222 Fuse Block - Underhood C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3223 Fuse Block - Underhood C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3224 Fuse Block - Underhood C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3225 Fuse Block - Underhood C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3226 Fuse Block - Underhood C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3227 Fuse Block - Underhood C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3228 Fuse Block - Underhood C2 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3229 Fuse Block - Underhood C2 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3230 Fuse Block - Underhood C3 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3231 Fuse Block - Underhood C3 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3232 Fuse Block - Underhood C4 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3233 Fuse Block - Underhood C4 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3234 Fuse Block - Underhood C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3235 Fuse Block - Underhood C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3236 Fuse Block - Underhood C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3237 Fuse Block - Underhood C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3238 Junction Block - I/P - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3239 Junction Block - I/P - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3240 Junction Block - I/P - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3241 Junction Block - I/P - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3242 Junction Block - I/P - C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3243 Junction Block - I/P - C8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3244 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3245 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3246 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3247 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3248 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3249 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3250 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3251 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3252 Relay Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3253 Relay Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3254 Relay Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3255 Relay Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3256 Relay Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3257 Relay Block - I/P C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3258 Relay Block - I/P C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3259 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3260 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3261 Relay Block - I/P C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3262 Relay Block - I/P C10 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label Fuse Block: Application and ID Fuse Block - I/P Label Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 3265 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 3266 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 3267 Fuse Block: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 3268 Fuse Block - Underhood Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 3269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 3270 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 3271 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 3272 Fuse Block: Application and ID Fuse Block - Underhood - Cooling Fan Fuse Block - Underhood - Cooling Fan Fuse Block - Underhood - Cooling Fan Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 3273 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3276 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3277 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3278 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3279 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3280 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3281 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 3286 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 3287 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 3288 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 3289 Relay Box: Locations Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 3290 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 3291 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3294 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3295 Relay Box: Diagrams Junction Block - Rear Lamps - C2 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3296 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3297 Relay Box: Diagrams Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3298 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3299 Relay Box: Diagrams Junction Block - Rear Lamps - C4 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3300 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3301 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3302 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3303 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3304 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3305 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3306 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3307 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3308 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3309 Junction Block - I/P - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3310 Junction Block - I/P - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3311 Junction Block - I/P - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3312 Junction Block - I/P - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3313 Junction Block - I/P - C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3314 Junction Block - I/P - C8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3315 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3316 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3317 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3318 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3319 Relay Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3320 Relay Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3321 Relay Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3322 Relay Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3323 Relay Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3324 Relay Block - I/P C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3325 Relay Block - I/P C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3326 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3327 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3328 Relay Block - I/P C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 3329 Relay Block - I/P C10 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 3332 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 3333 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 3334 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 3335 Relay Box: Application and ID Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 3336 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 3337 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 3340 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 3341 Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 3342 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 3343 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 3344 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 3345 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On MALFUNCTION INDICATOR LAMP (MIL) ALWAYS ON CIRCUIT DESCRIPTION Voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The MIL is located on the instrument panel cluster (IPC). MIL Function The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the diagnostic. MIL Illumination - The MIL will illuminate with ignition switch ON and the engine not running. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Intermittent Conditions TEST DESCRIPTION Steps 1-7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3351 The number below refers to the step number on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3352 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative MALFUNCTION INDICATOR LAMP (MIL) INOPERATIVE CIRCUIT DESCRIPTION Voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL OPERATION The MIL is located on the instrument panel cluster (IPC). MIL Function The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the PCM. MIL Illumination The MIL will illuminate with ignition switch ON and the engine not running. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3353 Steps 1-13 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3354 Steps 14-16 The number below refers to the step number on the diagnostic table. 4. This step tests for a short to voltage on the MIL control circuit. With the fuse removed there should be no voltage on the MIL control circuit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation ENGINE OIL LIFE SYSTEM WHEN TO CHANGE ENGINE OIL Your vehicle has a computer system that lets you know when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, you must reset the system every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A "CHANGE ENGINE OIL" message will come on. Change your oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if you are driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. It is also important to check your oil regularly and keep it at the proper level. If the system is ever reset accidentally, you must change your oil at 3,000 miles (5 000 km) since your last oil change. Remember to reset the oil life system whenever the oil is changed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 3358 Oil Change Reminder Lamp: Service and Repair ENGINE OIL LIFE SYSTEM HOW TO RESET THE ENGINE OIL LIFE SYSTEM The Engine Oil Life System calculates when to change your engine oil and filter based on vehicle use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change your oil prior to a "CHANGE ENGINE OIL" message being turned on, reset the system. To reset the "CHANGE ENGINE OIL" message do the following: 1. Turn the ignition key to "RUN" with the engine off. 2. Fully press and release the accelerator pedal slowly three times within five seconds. If the "OIL LIFE RESET" message flashes for 10 seconds, the system is resetting. 3. Turn the key to "LOCK". If the "CHANGE ENGINE OIL" message comes back on when you start your vehicle, the engine oil life system has not reset. Repeat the procedure. If it still does not reset, see your dealer for service. WHAT TO DO WITH USED OIL Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a service station or a local recycling center for help. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 3363 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. FRAME CONTACT HOIST Front Hoist Pads IMPORTANT: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 3364 Position the front hoist pads under the front frame between the lower control arm and the frame pad. Rear Hoist Pads IMPORTANT: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger SUSPENSION CONTACT HOIST Front Lift Position the front lift under the outer edge of the front suspension lower control arms. Rear Lift Position the rear lift under the axle housing tubes on each side of the differential. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 3365 Do not damage the stabilizer bar. JACKING When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails IMPORTANT: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. JACK STANDS When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3380 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3394 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 3400 Spare Tire: Service and Repair Tire Hoist and Shaft Replacement Tire Hoist Secondary Latch Mechanism Important: If the spare tire hoist has been fully raised without a spare tire in place, the secondary latch mechanism may have become engaged. If this has occurred the hoist will not lower and the following steps will need to be followed: 1. Rotate the hoist shaft counterclockwise until approximately 15 cm (6 inch) of cable (1) is exposed. 2. While holding the latch pin (3), fully depress the latch button (2) and release the secondary latch from the hoist assembly. Some side-to-side and/or up-and-down movement may be necessary to disengage the latch mechanism. 3. Continue rotating the hoist shaft counterclockwise in order to lower the hoist the rest of the way. 4. If this does not release the secondary latch, the spare tire hoist will need to be replaced. See the following procedure. Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and using the ignition key, remove the lock. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 3401 2. Rotate the hoist shaft counterclockwise in order to lower the spare tire to the ground. Continue to rotate the shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. Notice: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by rotating the hoist shaft clockwise until you hear two clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by rotating the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, rotate the hoist shaft counterclockwise until approximately 15 cm (6 inch) of cable is exposed. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, rotate the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is NOT visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Vehicle Lifting. 6. Depress the tabs, remove the guide shaft from the hoist collar, and slide the shaft toward the bumper. 7. Remove the collar from the hoist 8. Remove the bolt. 9. Remove the hoist from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 3402 10. Remove the spare tire hoist shaft guide from the bumper. Installation Procedure 1. Install the spare tire hoist shaft guide to the bumper. 2. Install the hoist to the crossmember. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 4. Install the collar to the hoist 5. Install the shaft to the hoist. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 3403 6. Install the spare tire to the hoist. 7. Rotate the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. Notice: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 8. Remove the safety stands. 9. Lower the vehicle. 10. Install the spare tire stowage lock cylinder. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3412 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3413 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3414 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3419 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3424 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3425 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3426 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: Customer Interest Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 3431 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3437 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3438 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3439 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3444 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3449 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3450 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3455 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3456 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3457 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3462 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3467 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3468 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3469 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: All Technical Service Bulletins Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 3478 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM Wheels: All Technical Service Bulletins Wheels/Tires - 20 Inch Wheels Available From GM Bulletin No.: 03-03-10-006F Date: September 27, 2006 INFORMATION Subject: 20" Wheels Available Through GM Accessories Models: 1999-2007 Chevrolet Silverado 1500 Series Only (Classic) 1999-2007 GMC Sierra 1500 Series Only (Classic) Excludes 1999-2000 Vehicles with 4.3L Engine (VIN W - RPO L35) Excludes Vehicles with Quadrasteer (RPO NYS) Excludes Parallel Hybrid Truck (RPO HP2) Excludes 2001-2004 Vehicles with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3483 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3484 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3485 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3486 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3487 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3488 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3489 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3490 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3496 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3497 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3498 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3503 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3508 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3509 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM Wheels: All Technical Service Bulletins Wheels/Tires - 20 Inch Wheels Available From GM Bulletin No.: 03-03-10-006F Date: September 27, 2006 INFORMATION Subject: 20" Wheels Available Through GM Accessories Models: 1999-2007 Chevrolet Silverado 1500 Series Only (Classic) 1999-2007 GMC Sierra 1500 Series Only (Classic) Excludes 1999-2000 Vehicles with 4.3L Engine (VIN W - RPO L35) Excludes Vehicles with Quadrasteer (RPO NYS) Excludes Parallel Hybrid Truck (RPO HP2) Excludes 2001-2004 Vehicles with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3518 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3519 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3520 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3521 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3522 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3523 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3524 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 3525 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. Important: Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M®, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 3528 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing A protective clear coating covers the surface of original equipment cast aluminum wheels. A surface degradation may develop if frequent automatic car wash cleaning wears off the factory applied protective clear coating. This can happen at some automatic car wash facilities that use aggressive brushes to clean whitewalls and tires. Once you damage the protective clear coating, exposure to caustic cleaners and road salt can cause further surface deterioration. Damage to the protective clear coating is corrected by replacing the damaged wheel. Refinishing is no longer recommended. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 3529 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Important: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. ^ Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel center cap. 3. Remove the wheel nuts from the tire and wheel. 4. Mark the location of the tire and wheel to the hub assembly. 5. Remove the tire and wheel from the vehicle. 6. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 3530 1. Install the tire and wheel. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. ^ Tighten the wheel nuts as shown to 190 Nm (140 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: ^ Tighten the nuts evenly and alternately in order to avoid excessive runout. 3. Install the wheel center cap. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 3535 Wheel Bearing: Fluid Type Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3536 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3537 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3538 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3539 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle Wheel Bearing: Service and Repair Rear Drive Axle Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting, See: Vehicle Lifting/Service and Repair 2. Remove the tire and wheel assembly, See: Service and Repair 3. Remove the brake caliper bracket. It is not necessary to remove the brake caliper from the bracket. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 4. Remove the axle shaft, See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3542 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3543 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3544 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). - Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Turn the wheel hub over and seat the outer bearing assembly against the retaining ring using the J 24426 (2) and the J 8092 (1). 7. Ensure that the outer bearing assembly rotates freely in the hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3545 8. Turn the wheel hub over and install the inner bearing cup. 9. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). 10. Install the inner bearing. 11. Install the new oil seal using the J 44420 (2) and the J 8092 (1). Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. 12. Install the rotor, if necessary, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair 13. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3546 14. Install the wheel hub to the axle housing. 15. Install the adjusting nut to the hub using the J 2222-C. 16. Adjust the wheel bearings. Refer to Wheel Bearing Adjustment, See: Adjustments 17. Install the axle shaft, See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair 18. Install the brake caliper bracket, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 19. Install the tire and wheel assembly, See: Service and Repair 20. Inspect and add axle lubricant to the axle housing, if necessary, See: Fluids/Fluid Differential/Service and Repair 21. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3547 Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3548 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3549 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3550 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3551 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3552 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3553 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3554 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3555 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3556 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3557 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3558 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 3559 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-002 > Mar > 05 > Wheels - Hubcaps Loose/Rattling Wheel Cover: Customer Interest Wheels - Hubcaps Loose/Rattling Info - Availability of New Functional Nut Caps For Steel Wheels # 05-03-10-002 - (Mar 21, 2005) Models: 2005 Chevrolet Silverado Models 2005 GMC Sierra Models with Steel Wheels Some vehicles may exhibit a condition of loose or rattling wheel hubcaps, especially on the front positions. This may be the result of brake heat distortion of the functional nut caps on the wheels. If this condition is encountered, only the functional nut caps in the hubcap assembly should be replaced, NOT the entire hubcap assembly. New functional nut caps, P/N 9596657, are now available. These new caps consist of more heat resistant material and are less susceptible to heat distortion. The new functional nut caps are dark gray in color. The original caps are black. Therefore, ALL functional nut caps on the vehicle must be replaced (24 functional nut caps on 6 bolt vehicles and 32 functional nut caps on 8 bolt vehicles). The old (black) functional nut caps should be snapped out of the hubcaps, and the new (dark gray) functional nut caps snapped back into place. When installing the hubcaps back on the vehicle, refer to Corporate Bulletin Number 03-03-10-002A. Use of Correct Installation Procedure for Loose Hubcap Assembly for the correct procedure for tightening the nut caps. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 03-03-10-002B > Nov > 05 > Wheels - Correct Hub Cap Installation Procedure Wheel Cover: All Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 03-03-10-002B > Nov > 05 > Wheels - Correct Hub Cap Installation Procedure > Page 3573 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 05-03-10-002 > Mar > 05 > Wheels - Hubcaps Loose/Rattling Wheel Cover: All Technical Service Bulletins Wheels - Hubcaps Loose/Rattling Info - Availability of New Functional Nut Caps For Steel Wheels # 05-03-10-002 - (Mar 21, 2005) Models: 2005 Chevrolet Silverado Models 2005 GMC Sierra Models with Steel Wheels Some vehicles may exhibit a condition of loose or rattling wheel hubcaps, especially on the front positions. This may be the result of brake heat distortion of the functional nut caps on the wheels. If this condition is encountered, only the functional nut caps in the hubcap assembly should be replaced, NOT the entire hubcap assembly. New functional nut caps, P/N 9596657, are now available. These new caps consist of more heat resistant material and are less susceptible to heat distortion. The new functional nut caps are dark gray in color. The original caps are black. Therefore, ALL functional nut caps on the vehicle must be replaced (24 functional nut caps on 6 bolt vehicles and 32 functional nut caps on 8 bolt vehicles). The old (black) functional nut caps should be snapped out of the hubcaps, and the new (dark gray) functional nut caps snapped back into place. When installing the hubcaps back on the vehicle, refer to Corporate Bulletin Number 03-03-10-002A. Use of Correct Installation Procedure for Loose Hubcap Assembly for the correct procedure for tightening the nut caps. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 03-03-10-002B > Nov > 05 > Wheels - Correct Hub Cap Installation Procedure Wheel Cover: All Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 03-03-10-002B > Nov > 05 > Wheels - Correct Hub Cap Installation Procedure > Page 3583 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Install the wheel drive shaft retaining nut. Tighten the nut to ................................................................................................................................. ........................................... 250 Nm (184 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3592 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3593 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3594 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3595 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 05-03-10-002 > Mar > 05 > Wheels - Hubcaps Loose/Rattling Wheel Fastener: Customer Interest Wheels - Hubcaps Loose/Rattling Info - Availability of New Functional Nut Caps For Steel Wheels # 05-03-10-002 - (Mar 21, 2005) Models: 2005 Chevrolet Silverado Models 2005 GMC Sierra Models with Steel Wheels Some vehicles may exhibit a condition of loose or rattling wheel hubcaps, especially on the front positions. This may be the result of brake heat distortion of the functional nut caps on the wheels. If this condition is encountered, only the functional nut caps in the hubcap assembly should be replaced, NOT the entire hubcap assembly. New functional nut caps, P/N 9596657, are now available. These new caps consist of more heat resistant material and are less susceptible to heat distortion. The new functional nut caps are dark gray in color. The original caps are black. Therefore, ALL functional nut caps on the vehicle must be replaced (24 functional nut caps on 6 bolt vehicles and 32 functional nut caps on 8 bolt vehicles). The old (black) functional nut caps should be snapped out of the hubcaps, and the new (dark gray) functional nut caps snapped back into place. When installing the hubcaps back on the vehicle, refer to Corporate Bulletin Number 03-03-10-002A. Use of Correct Installation Procedure for Loose Hubcap Assembly for the correct procedure for tightening the nut caps. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 05-03-10-002 > Mar > 05 > Wheels - Hubcaps Loose/Rattling Wheel Fastener: All Technical Service Bulletins Wheels - Hubcaps Loose/Rattling Info - Availability of New Functional Nut Caps For Steel Wheels # 05-03-10-002 - (Mar 21, 2005) Models: 2005 Chevrolet Silverado Models 2005 GMC Sierra Models with Steel Wheels Some vehicles may exhibit a condition of loose or rattling wheel hubcaps, especially on the front positions. This may be the result of brake heat distortion of the functional nut caps on the wheels. If this condition is encountered, only the functional nut caps in the hubcap assembly should be replaced, NOT the entire hubcap assembly. New functional nut caps, P/N 9596657, are now available. These new caps consist of more heat resistant material and are less susceptible to heat distortion. The new functional nut caps are dark gray in color. The original caps are black. Therefore, ALL functional nut caps on the vehicle must be replaced (24 functional nut caps on 6 bolt vehicles and 32 functional nut caps on 8 bolt vehicles). The old (black) functional nut caps should be snapped out of the hubcaps, and the new (dark gray) functional nut caps snapped back into place. When installing the hubcaps back on the vehicle, refer to Corporate Bulletin Number 03-03-10-002A. Use of Correct Installation Procedure for Loose Hubcap Assembly for the correct procedure for tightening the nut caps. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 3609 Wheel Fastener: Specifications Wheel Nut Torque ............................................................................................................................... ..................................................... 140 ft lb (190 Nm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 3610 Wheel Nut Torque Sequence Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel stud from the hub flange using the J 43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Refer to Brake Rotor Replacement Front in Disc Brakes. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 3613 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor, except dual wheel vehicles. 4. Remove the wheel stud from the axle flange using the J 43631. 5. Remove the axle shaft for vehicles with 9.5 in ring gear. 6. Remove the rear hub assembly for vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Remove the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Remove the wheel stud from the axle flange using the J 43631. 9. Remove the wheel stud from the hub flange using the J 43631. 10. Place the hub and rotor assembly in a press to remove the wheel stud. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 3614 1. Install the stud. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the axle shaft for the vehicles with 9.5 in ring gear. 6. Install the rear hub assembly for the vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Install the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Install the rotor, except dual wheels. 9. Install the tire and wheel. 10. Remove the safety stands. 11. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 3618 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 3619 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 3620 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help . Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 3624 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12-volt positive, negative ground electrical system. Do not try to jump start a vehicle, if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 1. Place the automatic transmission in PARK. 2. Block the wheels. 3. Set the parking brake. 4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 5. Turn OFF the ignition switch. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. Consult the vehicle's owner's manual for proper connections. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery.If the engine does not crank or cranks too slowly, perform the following steps: 0. Turn the ignition OFF. 1. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 2. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 3628 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. FRAME CONTACT HOIST Front Hoist Pads IMPORTANT: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 3629 Position the front hoist pads under the front frame between the lower control arm and the frame pad. Rear Hoist Pads IMPORTANT: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger SUSPENSION CONTACT HOIST Front Lift Position the front lift under the outer edge of the front suspension lower control arms. Rear Lift Position the rear lift under the axle housing tubes on each side of the differential. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 3630 Do not damage the stabilizer bar. JACKING When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails IMPORTANT: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. JACK STANDS When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 3636 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Check the compression again and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Retainer Bolt ....................................................................................................................... ..................................................... 25 Nm (18 lbs. ft.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair Camshaft: Service and Repair Camshaft Replacement Removal Procedure 1. Raise the hood to the service position, perform the following: ^ Remove the hood hinge bolts (1). ^ Raise the hood until vertical. ^ Install the hood hinge bolts until snug in the service position (2). 2. Remove the radiator support. 3. Remove the front cover. 4. Remove the valve lifters. 5. Remove the camshaft sensor bolt and sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 3644 6. Rotate the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned. 7. Remove the camshaft sprocket bolts. 8. Notice: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. Remove the camshaft sprocket and reposition the timing chain. 9. Remove the camshaft retainer bolts and retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 3645 10. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. Remove the camshaft. 1. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 inch) bolts to the bolt holes in the front of the camshaft. 2. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. 3. Remove the three bolts from the camshaft. 11. If required, clean and inspect the camshaft and bearings. Installation Procedure Important: If camshaft replacement is required, the valve lifters must also be replaced. 1. Lubricate the camshaft journals and the bearings with clean engine oil. 2. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 inch) bolts to the bolt holes in the front of the camshaft. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 3. Using the bolts as a handle, carefully install the camshaft into the engine block. 4. Remove the three bolts from the front of the camshaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 3646 5. Notice: Refer to Fastener Notice in Service Precautions. Important: Install the retainer plate with the sealing gasket facing the engine block. The gasket surface on the engine block should be clean and free of dirt and/or debris. Install the camshaft retainer and bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Install the camshaft sprocket and position the timing chain. 7. Install the camshaft sprocket bolts. Tighten the bolts to 35 Nm (26 ft. lbs.). 8. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be reused. 9. Lubricate the O-ring seal with clean engine oil. 10. Install the camshaft sensor and bolt. Tighten the bolt to 25 Nm (18 ft. lbs.). 11. Install the valve lifters. 12. Install the front cover. 13. Install the radiator support. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 3647 14. Remove the hood hinge bolts from the service position (2). 15. Lower the hood to the normal position. 16. Install the hood hinge bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement Tools Required ^ J3049-A Valve Lifter Remover Removal Procedure 1. Remove the cylinder head and gasket. 2. Remove the valve lifter guide bolts. 3. Remove the valve lifters and guide. 4. Important: Some valve lifters may be stuck in their bores because of gum or varnish deposits. Use J3049-A or equivalent in order to remove the valve lifters, if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 3651 5. Remove the valve lifters from the guide. 6. Organize or mark the components so that they can be installed in the same location from which they were removed. 7. If required, clean and inspect the valve lifters. Installation Procedure Important: When reusing valve lifters, install the lifters to their original locations. 1. Lubricate the valve lifters and engine block valve lifter bores with clean engine oil. 2. Insert the valve lifters into the lifter guides. Align the flat area on the top of the lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore. 3. Install the valve lifters and guide to the engine block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 3652 4. Notice: Refer to Fastener Notice in Service Precautions. Install the valve lifter guide bolts. Tighten the bolt to 12 Nm (106 inch lbs.). 5. Install the cylinder head and gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Important: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 2. Remove the rocker arm bolts. 3. Remove the rocker arms. 4. Remove the rocker arm pivot support. 5. Remove the pushrods. 6. If required, clean and inspect the rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 3656 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. 4. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Install the pushrods. 5. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. Install the rocker arms and bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 3657 6. Rotate the crankshaft until the number one piston is at Top Dead Center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinder 2, 4, 6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following rocker arm bolts: ^ Tighten cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: ^ Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the rocker arm cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Important: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 2. Remove the rocker arm bolts. 3. Remove the rocker arms. 4. Remove the rocker arm pivot support. 5. Remove the pushrods. 6. If required, clean and inspect the rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 3661 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. 4. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Install the pushrods. 5. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. Install the rocker arms and bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 3662 6. Rotate the crankshaft until the number one piston is at Top Dead Center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinder 2, 4, 6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following rocker arm bolts: ^ Tighten cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: ^ Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the rocker arm cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Clearance - Production .................................................................................................. 0.023 - 0.065 mm (0.0009 - 0.0025 inch) Connecting Rod Bearing Clearance - Service ......................................................................................................... 0.023 - 0.076 mm (0.0009 0.003 inch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - Revised Connecting Rod Bolt Torque Connecting Rod: Technical Service Bulletins Engine - Revised Connecting Rod Bolt Torque Bulletin No.: 07-06-01-002 Date: March 05, 2007 INFORMATION Subject: Information on Revised Connecting Rod Bolt Torque for Small Block GEN III and GEN IV Vortec(TM) V8 Engines Models A new connecting rod bolt torque specification was introduced to the GEN III and GEN IV Vortec(TM) small block V8 engines. The connecting rod bolts should continue to be tightened using two passes. The second pass value has been increased from 75 degrees to 85 degrees. Install the connecting rod bolts and tighten. Refer to Piston, Connecting Rod, and Bearing Installation in SI. Tighten Tighten the connecting rod bolts a first pass to 20 N.m (15 lb ft). Tighten the connecting rod bolts a final pass to 85 degrees using the J 45059 Angle Meter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - Revised Connecting Rod Bolt Torque > Page 3671 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Page 3672 Connecting Rod: Specifications Connecting Rod Side Clearance .................................................................................................................................. 0.11 - 0.51 mm (0.00433 - 0.02 inch) Connecting Rod Journal Diameter - Production ................................................................................................ 53.318 - 53.338 mm (2.0991 - 2.0999 inch) Connecting Rod Journal Diameter - Service ................................................................................................................................. 53.308 mm (2.0987 inch) Connecting Rod Journal Out-of-Round - Production ....................................................................................................................... 0.005 mm (0.0002 inch) Connecting Rod Journal Out-of-Round - Service .............................................................................................................................. 0.01 mm (0.0004 inch) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production ....................................................................... 0.005 mm (0.0002 inch) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service ............................................................................. 0.02 mm (0.00078 inch) Connecting Rod Bore Diameter - Bearing End ..................................................................................................... 56.505 56.525 mm (2.224 - 2.225 inch) Connecting Rod Bore Out-of-Round - Bearing End - Production ....................................................................... 0.004 - 0.008 mm (0.00015 - 0.0003 inch) Connecting Rod Bore Out-of-Round - Bearing End - Service ............................................................................ 0.004 - 0.008 mm (0.00015 - 0.0003 inch) Connecting Rod Bolts - First Pass ............................................................................................................................................................ 20 Nm (15 ft. lbs.) Connecting Rod Bolts - Final Pass ........................................................................ ................................................................................................ 85 degrees Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main Bearing Cap Tighten the bearing cap bolts and studs. Tighten the inner M10 bearing cap bolts first pass in sequence ........................................................................................................... 20 Nm (15 ft. lbs.) Using a plastic faced hammer, tap the crankshaft rearward then forward to align the thrust bearings. Tighten the inner M10 bolts final pass in sequence ............................................................................................................. 80 degrees using the J45059. Tighten the outer M10 bolts/studs first pass in sequence ..................................................................................................................... 20 Nm (15 ft. lbs.) Tighten the outer M10 bolts/studs final pass in sequence .................................................................................................... 51 degrees using the J45059. Tighten the bearing cap side M8 bolts to ................. 25 Nm (18 ft. lbs.) Tighten the bolt on one side of the bearing cap and then tighten the bolt on the opposite side of the same bearing cap. Crankshaft Main Bearing Clearance - Production ................................................................................................... 0.02 - 0.052 mm (0.0008 - 0.0021 inch) Crankshaft Main Bearing Clearance - Service ........................................................................................................ 0.02 - 0.065 mm (0.0008 0.0025 inch) Crankshaft Main Bearing Bore Diameter ................................................................................................................ 69.871 - 69.889 mm (2.75 2.751 inch) Crankshaft Main Bearing Bore Out-of-Round ................................................................................................................................. 0.006 mm (0.0002 inch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Main Journal Diameter - Production ................................................................................................... 64.992 - 65.008 mm (2.558 - 2.559 inch) Crankshaft Main Journal Diameter - Service ................................................................................................................................... 64.992 mm (2.558 inch) Crankshaft Main Journal Out-of-Round - Production .................................................................................................................. 0.003 mm (0.000118 inch) Crankshaft Main Journal Out-of-Round - Service ........................................................................................................................... 0.008 mm (0.0003 inch) Crankshaft Main Journal Taper - Production ..................................................................................................................................... 0.01 mm (0.0004 inch) Crankshaft Main Journal Taper - Service ........................................................................................................................................ 0.02 mm (0.00078 inch) Crankshaft End Play .................................................................................................................................................... 0.04 - 0.2 mm (0.0015 - 0.0078 inch) Crankshaft Rear Flange Runout ........................................................................................................................................................... 0.05 mm (0.002 inch) Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 inch) Below Tooth Diameter .................................................................. 0.7 mm (0.028 inch) Crankshaft Thrust Surface - Production .................................................................................................................. 26.14 - 26.22 mm (1.029 - 1.0315 inch) Crankshaft Thrust Surface - Service ................................................................................................................................................ 26.22 mm (1.0315 inch) Crankshaft Thrust Surface Runout ..................................................................................................................................................... 0.025 mm (0.001 inch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Engine Block Heater: Service and Repair Coolant Heater Coolant Heater Replacement (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Raise and suitably support the vehicle. 3. Disconnect the coolant heater electrical connector (2). 4. Important: Do not score the surface of the engine block hole when removing the coolant heater. Remove the coolant heater from the engine block. 5. Remove any burrs, sealer, paint or other rough spots. Installation Procedure 1. If re-using the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the coolant heater to the engine block. Tighten the coolant heater to 50 Nm (37 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater > Page 3683 3. Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. Connect the coolant heater electrical connector (2). 4. Lower the vehicle. 5. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater > Page 3684 Engine Block Heater: Service and Repair Heater Cord Coolant Heater Cord Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the coolant heater electrical connector (2). 3. Remove the coolant heater cord retainer and bolts. 4. Remove the coolant heater cord. Installation Procedure Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. 1. Install the coolant heater cord. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the coolant heater cord bolts and retainer. Tighten the bolts to 8 Nm (71 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater > Page 3685 3. Connect the coolant heater electrical connector (2). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Service and Repair Engine Valley Cover: Service and Repair Engine Valley Cover Replacement Removal Procedure 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. 5. Remove the engine valley cover bolts. 6. Remove the engine valley cover and gasket. 7. Discard the old gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Service and Repair > Page 3689 8. Remove the knock sensor oil seals (1) from the cover (2). 9. If required, clean and inspect the engine valley cover. Installation Procedure Important: All gasket surfaces should be free of oil or other foreign material during assembly. 1. Lubricate the NEW knock sensor seals (1) with clean engine oil. 2. Install the knock sensor oil seals (1) into the engine valley cover (2). 3. Install the engine valley cover with a NEW gasket onto the engine block. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the engine valley cover bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 5. Install the knock sensors. Tighten the sensors to 20 Nm (15 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Service and Repair > Page 3690 6. Connect the knock sensor electrical connectors. 7. Push down on the rubber covers. 8. Install the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Tighten the USED crankshaft balancer bolt ........................................................................................................................................ 330 Nm (240 ft. lbs.) Remove the used crankshaft balancer bolt. Important: The nose of the crankshaft should be recessed 2.4 - 4.48 mm (0.094 - 0.176 inch) into the balancer bore. Install a NEW crankshaft balancer bolt. Tighten the bolt a first pass ................................................................................................................. .................................................. 50 Nm (37 ft. lbs.) Tighten the bolt a second pass ................................................................................................................................................. 140 degrees using J45059. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3694 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement (4.8L, 5.3L, and 6.0L Engines) Tools Required ^ J41816 Crankshaft Balancer Remover ^ J41816-2 Crankshaft End Protector ^ J42386-A Flywheel Holding Tool ^ J41665 Crankshaft Balancer and Sprocket Installer ^ J45059 Angle Meter Removal Procedure 1. Remove the Air Conditioning (A/C) drive belt. 2. Remove the fan shroud - lower. 3. Remove the starter motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Important: ^ Make sure that the teeth of the J42386-A mesh with the teeth of the engine flywheel. ^ The crankshaft balancer is balanced as an individual component. It is not necessary to mark the balancer prior to removal. Install the J42386-A and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten the J42386-A bolts to 50 Nm (37 ft. lbs.). 5. Remove the crankshaft balancer bolt. Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3695 6. Use the J41816 and J41816-2 in order to remove the crankshaft balancer. 7. Remove the J41816 and the J41816-2 from the crankshaft balancer. 8. Clean and inspect the crankshaft balancer. Installation Procedure Important: ^ Make sure that the teeth of J42386-A mesh with the teeth of the engine flywheel. ^ The used crankshaft balancer bolt will be used only during the first pass of the balancer installation procedure. Install a NEW bolt and tighten as described in the second, third and forth passes of the balancer bolt tightening procedure. ^ The crankshaft balancer installation and bolt tightening involves a four stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The second, third, and forth passes tighten the new bolt to the proper torque. Important: The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation. 1. Install the crankshaft balancer onto the end of the crankshaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3696 2. Use the J41665 in order to install the crankshaft balancer. 1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. 2. Use a wrench and hold the hex end of the threaded rod. 3. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. 4. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. 5. Use a wrench and hold the hex end of the threaded rod. 6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. 7. Remove the balancer installation tool. 3. Install the used crankshaft balancer bolt. Tighten the USED crankshaft balancer bolt to 330 Nm (240 ft. lbs.). 4. Remove the used crankshaft balancer bolt. Important: The nose of the crankshaft should be recessed 2.4 - 4.48 mm (0.094 - 0.176 inch) into the balancer bore. 5. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install the J41665 and repeat the installation procedure. 6. Install a NEW crankshaft balancer bolt. 1. Tighten the bolt a first pass to 50 Nm (37 ft. lbs.). 2. Tighten the bolt a second pass to 140 degrees using J45059. 7. Remove the J42386-A and bolts. 8. Install the starter motor. 9. Install the fan shroud - lower. 10. Install the A/C drive belt. 11. Perform the Crankshaft Position (CKP) system variation learn procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Pin - Piston Pin Clearance to Piston Pin Bore - Production .................................................................................. 0.002 - 0.01 mm (0.00008 - 0.0004 inch) Pin Piston Pin Clearance to Piston Pin Bore - Service ...................................................................................... 0.002 - 0.015 mm (0.00008 - 0.0006 inch) Pin - Piston Pin Diameter ...................................................................................................................................... 23.952 23.955 mm (0.943 - 0.943 inch) Pin - Piston Pin Fit in Connecting Rod Bore - Production .................................................................................. 0.007 - 0.02 mm (0.00027 - 0.00078 inch) Pin Piston Pin Fit in Connecting Rod Bore - Service ...................................................................................... 0.007 - 0.022 mm (0.00027 - 0.00086 inch) Piston - Piston Diameter - Measured Over Skirt Coating ........................................................................................ 96.002 - 96.036 mm (3.779 - 3.78 inch) Piston - Piston to Bore Clearance - Production ............................................................................................... -0.036 to 0.016 mm (-0.0014 to 0.0006 inch) Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off ............................................................................. 0.071 mm (0.0028 inch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production ......................................... 0.23 - 0.44 mm (0.009 - 0.017 inch) Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service .............................................. 0.23 - 0.5 mm (0.009 - 0.0196 inch) Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production ...................................... 0.44 - 0.7 mm (0.017 - 0.027 inch) Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service .......................................... 0.44 - 0.76 mm (0.0173 - 0.03 inch) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production .................................................... 0.18 - 0.75 mm (0.007 - 0.029 inch) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service ......................................................... 0.18 - 0.81 mm (0.007 - 0.032 inch) Piston Ring to Groove Clearance - First Compression Ring Production .......................................................... 0.04 - 0.085 mm (0.00157 - 0.00335 inch) Piston Ring to Groove Clearance - First Compression Ring - Service ................................................................ 0.04 - 0.085 mm (0.00157 - 0.00335 inch) Piston Ring to Groove Clearance - Second Compression Ring - Production ........................................................ 0.04 - 0.078 mm (0.00157 - 0.0031 inch) Piston Ring to Groove Clearance - Second Compression Ring - Service .............................................................. 0.04 - 0.078 mm (0.00157 - 0.0031 inch) Piston Ring to Groove Clearance - Oil Control Ring - Production ........................................................................... 0.012 - 0.2 mm (0.0005 - 0.0078 inch) Piston Ring to Groove Clearance - Oil Control Ring - Service ................................................................................. 0.012 - 0.2 mm (0.0005 - 0.0078 inch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair Rear Engine Plate: Service and Repair Engine Rear Cover Replacement Tools Required ^ J41476 Front and Rear Cover Alignment Tool Removal Procedure 1. Remove the engine flywheel. 2. Remove the oil pan-to-rear cover bolts (1). 3. Remove the rear cover bolts. 4. Remove the rear cover and gasket. 5. Discard the rear cover gasket. 6. If required, clean and inspect the rear cover. Installation Procedure Important: ^ Do not reuse the crankshaft oil seal or rear cover gasket. ^ Do not apply any type of sealant to the rear cover gasket (unless specified). ^ The special tool in this procedure is used to properly center the crankshaft rear oil seal. ^ The crankshaft rear oil seal will be installed after the rear cover has been installed and aligned. Install the rear cover without the crankshaft oil seal. All gasket surfaces should be free of oil or other foreign material during assembly. - The crankshaft rear oil seal MUST be centered in relation to the crankshaft. - An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair > Page 3706 1. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 inch) long to the oil pan to engine block junction. 2. Install the rear cover gasket and cover. 3. Install the rear cover bolts until snug. Do not overtighten. 4. Install the oil pan-to-rear cover bolts (1) until snug. Do not overtighten. 5. Rotate the crankshaft until two opposing flywheel bolt holes are parallel to the oil pan surface. Important: The tapered legs of the alignment tool must enter the rear cover oil seal bore. 6. Install the J41476 and bolts onto the rear of the crankshaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair > Page 3707 Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the J41476 mounting bolts until snug. Do not overtighten. 1. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 inch lbs.). 2. Tighten the engine rear cover bolts to 25 Nm (18 ft. lbs.). 8. Remove the J41476. 9. Install a NEW crankshaft rear oil seal. 10. Install the engine flywheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3713 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. Refer to Fuel Pressure Gage Installation and Removal. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Important: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 2. Remove the rocker arm bolts. 3. Remove the rocker arms. 4. Remove the rocker arm pivot support. 5. Remove the pushrods. 6. If required, clean and inspect the rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 3717 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. 4. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Install the pushrods. 5. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. Install the rocker arms and bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 3718 6. Rotate the crankshaft until the number one piston is at Top Dead Center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinder 2, 4, 6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following rocker arm bolts: ^ Tighten cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: ^ Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the rocker arm cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Left) Valve Rocker Arm Cover Replacement - Left Removal Procedure 1. Remove the engine sight shield, if required. 2. Remove the Connector Position Assurance (CPA) lock. 3. Disconnect the main electrical connector (2) to the ignition coil wire harness. 4. Remove the harness clips (1). 5. Reposition the engine harness, if necessary. 6. Remove the spark plug wires from the ignition coils. ^ Twist each plug wire 1/2 turn. ^ Pull only on the boot in order to remove the wire from the ignition coil. 7. Remove the ignition coil bracket studs. 8. Remove the ignition coil bracket. 9. Remove the positive crankcase ventilation (PCV) hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3723 10. Loosen the valve rocker arm cover bolts. 11. Remove the valve rocker arm cover. 12. Remove and discard the old gasket (1). 13. If required, clean and inspect the rocker arm cover. Installation Procedure Important: ^ All gasket surfaces should be free of oil an/or other foreign material during assembly. ^ DO NOT reuse the valve rocker arm cover gasket. ^ If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet during assembly. 1. Install a NEW rocker cover gasket (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3724 2. Install the valve rocker arm cover. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the rocker arm cover bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 4. Install the PCV hose. 5. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the bracket bolts. 6. Install the ignition coil bracket. 7. Install the ignition coil bracket studs. Tighten the studs to 12 Nm (106 inch lbs.). 8. Install the spark plug wires to the ignition coils. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3725 9. Position the engine harness, if necessary. 10. Install the harness clips (1). 11. Connect the main electrical connector (2) to the ignition coil wire harness. 12. Install the CPA lock. 13. Install the engine sight shield, if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3726 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Right) Valve Rocker Arm Cover Replacement - Right Removal Procedure 1. Remove the engine sight shield, if required. 2. Remove the connector position assurance (CPA) lock (5). 3. Disconnect the main electrical connector (4) to the ignition coil wire harness. 4. Remove the harness clips (1). 5. Reposition the engine harness, if necessary. 6. Remove the spark plug wires from the ignition coils. ^ Twist each plug wire 1/2 turn. ^ Pull only on the boot in order to remove the wire from the ignition coil. 7. Reposition the surge tank/heater hoses from the heater hose bracket. 8. Remove the heater hose bracket nut and bracket. 9. Remove the ignition coil bracket studs. 10. Remove the ignition coil bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3727 11. Remove the positive crankcase ventilation (PCV) hose. 12. Loosen the valve rocker arm cover bolts. 13. Remove the valve rocker arm cover. 14. Remove and discard the old gasket (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3728 15. Remove the oil fill tube from the rocker cover, if required. 16. If required, clean and inspect the rocker arm cover. Installation Procedure Important: ^ All gasket surfaces should be free of oil or other foreign material during assembly. ^ DO NOT reuse the valve rocker arm cover gasket. ^ If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly. 1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil. 2. Insert the NEW oil fill tube into the rocker arm cover. Rotate the tube clockwise until locked in the proper position. 3. Install the oil fill cap into the tube. Rotate the cap clockwise until locked in the proper position. 4. Install a NEW rocker cover gasket (1) into the valve rocker arm cover lip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3729 5. Install the valve rocker arm cover. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the rocker arm cover bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 7. Install the PCV hose. 8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the bracket bolts. 9. Install the ignition coil bracket. 10. Install the ignition coil bracket studs. Tighten the studs to 12 Nm (106 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3730 11. Install the heater hose bracket and nut. Tighten the nut to 9 Nm (80 inch lbs.). 12. Position the surge tank/heater hoses to the heater hose bracket. 13. Install the spark plug wires to the ignition coils. 14. Position the engine harness, if necessary. 15. Install the harness clips (1). 16. Connect the main electrical connector (4) feeding the ignition coils. 17. Install the CPA lock (5). 18. Install the engine sight shield, if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Tools Required ^ J22794 Spark Plug Port Adapter ^ J38606 Valve Spring Compressor Removal Procedure 1. Remove the rocker arm. 2. Disconnect the spark plug wire at the spark plug. ^ Twist each plug wire boot 1/2 turn. ^ Pull only on the boot in order to remove the wire from the spark plug. 3. Important: Remove the spark plugs from the cylinder head with the engine at room temperature. Loosen the spark plug 1 or 2 turns. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3734 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install the J22794 into the spark plug hole. 7. Attach an air hose to the J22794. 8. Apply compressed air to the J22794 in order to hold the valves in place. 9. Use the J38606 in order to compress the valve spring. 10. Remove the valve stem keys (2). 11. Carefully release the valve spring tension. 12. Remove the J38606. 13. Remove the valve spring cap (3). 14. Remove the valve spring (4). 15. Remove the valve stem oil seal and shim (1, 5) Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3735 1. Clean the cylinder head valve spring seat and/or shim area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valve stem oil seal and shim (1, 5). 4. Install the valve spring (4). 5. Install the valve spring cap (3). 6. Compress the valve spring using the J38606. 7. Install the valve keys. ^ Use grease in order to hold the valve keys in place. ^ Make sure the keys seat properly in the groove of the valve stem. ^ Carefully release the valve spring pressure, making sure the valve keys stay in place. ^ Remove the J38606. ^ Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3736 8. Remove the J22794 from the spark plug port. 9. Notice: Refer to Fastener Notice in Service Precautions. Hand start the spark plug. Tighten the spark plug to 15 Nm (11 ft. lbs.). 10. Install the spark plug wires at the ignition coil. 11. Install the spark plug wire to the spark plug. 12. Inspect the wires for proper installation: ^ Push sideways on each boot in order to check for proper installation. ^ Reinstall any loose boot. 13. Install the rocker arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 3742 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 3743 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Accessory Drive Belt Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Accessory Drive Belt > Page 3746 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3747 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3750 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3751 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3752 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3753 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3754 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3755 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3756 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3757 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3758 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3759 Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3760 An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3761 Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3762 the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body, or suspension component, or other item(s) on the vehicle may cause the squeal noise. If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying their load(s), making sure they are operating to their maximum capacity. An overcharged Air Conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further in this table 3. The squeal may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt(s) or an accessory drive component. With the drive belt(s) removed the water pump will not operate and the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3763 engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This test is to verify that an accessory drive component(s) does not have a seized bearing. With the belt(s) removed, test the bearings in the accessory drive component(s) for smooth operation. Also test the accessory drive component(s) with the engine operating by varying the load on the accessory drive component(s) to verify that the component(s) is operating properly. 5. This test is to verify that the drive belt(s) tensioner(s) are not operating properly. If the drive belt tensioner(s) are not operating properly, proper belt tension may not be achieved to keep the drive belt(s) from slipping which could cause a squealing noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 8. Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys. Drive Belt Vibration Drive Belt Vibration Diagnosis Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3764 Diagnostic Aids The accessory drive components may have an affect on engine vibration. An overcharged Air Conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the drive belt(s). 6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange. 9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known, good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3765 Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine. If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their loads, making sure they are operating to their maximum capacity. An overcharged Air Conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3766 The number(s) below refer to the step(s) in the diagnostic table. 3. This test is to verify that the whine is being caused by the accessory drive component(s). Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory Drive Belt: Service and Repair Drive Belt Replacement - Accessory Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Loosen the air cleaner outlet duct clamps at the following locations: ^ The throttle body ^ The Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 2. Disconnect the radiator inlet hose clip from the outlet duct. 3. Remove the air cleaner outlet duct. 4. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 5. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt (1). 6. Remove the belt (1) from the pulleys and the drive belt tensioner. 7. Slowly release the tension on the drive belt tensioner. 8. Remove the breaker bar and socket and from the drive belt tensioner bolt. 9. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt (1) under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 3769 7. Inspect the drive belt (1) for proper installation and alignment. 8. Align the arrow (2) at the throttle body end of the duct with the throttle body attaching stud (1). 9. Install the air cleaner outlet duct. 10. Connect the radiator inlet hose clip to the outlet duct. Notice: Refer to Fastener Notice in Service Precautions. 11. Tighten the air cleaner outlet duct clamps at the following locations: ^ The throttle body ^ The MAF/IAT sensor Tighten the clamps to 4 Nm (35 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 3770 Drive Belt: Service and Repair Drive Belt Replacement - Air Conditioning Drive Belt Replacement - Air Conditioning Removal Procedure 1. Remove the accessory drive belt. 2. Raise and suitably support the vehicle. 3. Remove the engine shield bolts. 4. Remove the engine shield. 5. Install a ratchet into the Air Conditioning (A/C) belt tensioner adapter opening. 6. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt. 7. Remove the A/C belt from the pulleys. 8. Slowly release the tension on the A/C belt tensioner. 9. Remove the ratchet from the A/C belt tensioner. 10. Clean and inspect the belt surfaces of all the pulleys. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 3771 Installation Procedure 1. Install the A/C belt around the crankshaft balancer. 2. Install a ratchet into the A/C drive belt tensioner adapter opening 3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the tensioner. 4. Install the A/C belt over the idler pulley. 5. Install the A/C belt around the A/C compressor pulley. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the ratchet from the A/C belt tensioner. 8. Inspect the A/C belt for proper installation and alignment. 9. Install the engine shield. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the engine shield bolts. Tighten the bolts to 20 Nm (15 ft. lbs.). 11. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 3772 12. Install the accessory drive belt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Inspection Procedure 1. Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. Important: When the engine is operating the drive belt tensioner arm will move. Do not replace the drive belt tensioner because of movement in the drive belt tensioner arm. Remove the drive belt. 2. Move the drive belt tensioner through its full travel. ^ The movement should feel smooth. ^ There should be no binding. ^ The tensioner should return freely. 3. If any binding is observed, replace the drive belt tensioner. 4. Install the drive belt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Drive Belt Tensioner Replacement - Accessory Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement - Accessory Drive Belt Tensioner Replacement - Accessory Removal Procedure 1. Remove the accessory drive belt. 2. Remove the drive belt tensioner bolts. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner. 2. Install the drive belt tensioner bolts. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the drive belt tensioner bolts. Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the accessory drive belt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Drive Belt Tensioner Replacement - Accessory > Page 3778 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement - Air Conditioning Drive Belt Tensioner Replacement - Air Conditioning Removal Procedure 1. Remove the Air Conditioning (A/C) drive belt. 2. Remove the A/C belt tensioner bolts. 3. Remove the A/C belt tensioner. Installation Procedure 1. Install the A/C belt tensioner. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the A/C belt tensioner bolts. Tighten the bolts to 50 Nm (37 ft. lbs.). 3. Install the A/C drive belt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. Notice: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Measure the engine movement at the engine mount in order to check for damage to the rubber portions of the mount. 1. Apply the park brake. 2. Start the engine. 3. Firmly apply and hold the primary brakes. 4. Have an assistant stand to the side of the vehicle in order to observe for engine movement. 5. Slightly load the engine shifting from drive to reverse a few times. 6. If the engine moves more than 24 mm (0.945 inch) from the at rest position, in either direction, check for loose engine mount bolts. 2. If the engine mount bolt torque is within specifications, check the condition of the engine mount. 3. Replace the engine mount if any of the following conditions exist: ^ Heat check cracks cover the rubber cushion surface. ^ The rubber cushion is separated from the metal plate of the mount. ^ There is a split through the rubber cushion. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left Engine Mount: Service and Repair Engine Mount Bracket Replacement - Left Engine Mount Bracket Replacement - Left Removal Procedure 1. Remove the engine mount. 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure 1. Install the engine mount bracket. 2. Perform the following procedure prior to installing the engine mount bracket bolts. ^ Remove all traces of the original adhesive patch. ^ Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. ^ Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolts. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the engine mount bracket bolts. Tighten the engine mount bracket bolts to 75 Nm (55 ft. lbs.). 4. Install the engine mount. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 3784 Engine Mount: Service and Repair Engine Mount Bracket Replacement - Right Engine Mount Bracket Replacement - Right Removal Procedure 1. Remove the engine mount. 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure 1. Install the engine mount bracket. 2. Perform the following procedure prior to installing the engine mount bracket bolts. ^ Remove all traces of the original adhesive patch. ^ Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. ^ Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolts. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the engine mount bracket bolts. Tighten the engine mount bracket bolts to 75 Nm (55 ft. lbs.). 4. Install the engine mount. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 3785 Engine Mount: Service and Repair Engine Mount Replacement Engine Mount Replacement - Left Engine Mount Replacement - Left Removal Procedure Notice: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Raise the vehicle. 2. Remove the tire and wheel. 3. Remove the wheelhouse panel from the vehicle. 4. For vehicles with 4WD, remove the front propeller shaft. 5. Important: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan. Raise and suitably support the engine using adjustable (screw type) jack stands. 6. Remove the engine mount-to-engine mount bracket bolts. (Right side shown, left side similar). 7. Remove the engine mount bolts. 8. Remove the left engine mount. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 3786 1. Install the left engine mount to the engine. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bolts to the engine. Tighten the engine mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the engine. 4. Remove the adjustable jack stands. 5. For vehicles with 4WD, install the front propeller shaft. 6. Install the engine mount-to-engine mount bracket bolts. (Right side shown, left side similar). Tighten the engine mount-to-engine mount bracket bolts to 65 Nm (48 ft. lbs.). 7. Install the wheelhouse panel from the vehicle. 8. Install the tire and wheel. 9. Lower the vehicle. Engine Mount Replacement - Right Engine Mount Replacement - Right Removal Procedure 1. Remove the exhaust manifold. 2. Remove the engine mount-to-engine mount bracket bolts. 3. Raise and suitably support the vehicle. 4. Remove the tire and wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 3787 5. Remove the inner wheelhouse panel. 6. Remove the engine protection shield, if equipped. 7. Important: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan. Raise and suitably support the engine using adjustable (screw type) jack stands. 8. Remove the engine mount to engine bolts. 9. Remove the right engine mount. Installation Procedure 1. Position the right engine mount to the engine. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bolts. Tighten the engine mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the engine. 4. Remove the adjustable jack stands. 5. Install the engine mount-to-engine mount bracket bolts. Tighten the engine mount-to-engine mount bracket bolts to 65 Nm(48 ft. lbs.). 6. Install the exhaust manifold. 7. Install the inner wheelhouse panel. 8. Install the tire and wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 3788 9. Install the engine protection shield, if equipped. 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Loosen the drive belt idler pulley bolt. 2. Remove the accessory drive belt. 3. Remove the drive belt idler pulley and bolt. Installation Procedure 1. Install the drive belt idler pulley and bolt to the generator bracket. Snug the bolt finger tight. 2. Install the drive belt. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the drive belt idler pulley bolt. Tighten the bolt to 50 Nm (37 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - Hot .................... 41 kPa at 1,000 engine RPM (124 kPa at 2,000 engine RPM) 165 kPa at 4,000 engine RPM (6 psig at 1,000 engine RPM) 18 psig at 2,000 engine RPM (24 psig at 4,000 engine RPM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 3796 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Tools Required ^ J21867 Pressure Gage ^ J42907 Oil Pressure Testing Tool 1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10 - 15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following conditions: ^ Oil diluted by water or glycol anti freeze ^ Foamy oil 6. Remove the oil filter and install the J42907. 7. Install J21867 or equivalent to the J42907. 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications (LR4 VIN V) Engine Mechanical Specifications (LM7 VIN T) Engine Mechanical Specifications (L59 VIN Z) Engine Mechanical Specifications (LQ4 VIN U) Engine Mechanical Specifications (LQ9 VIN N). 10. If the engine oil pressure is below specifications, inspect the engine for one or more of the following conditions: ^ Oil pump worn or dirty. ^ Oil pump-to-engine block bolts loose. ^ Oil pump screen loose, plugged, or damaged ^ Oil pump screen O-ring seal missing or damaged ^ Malfunctioning oil pump pressure relief valve ^ Excessive bearing clearance ^ Cracked, porous, or restricted oil galleries ^ Oil gallery plugs missing or incorrectly installed. ^ Broken valve lifters. Repair as necessary. 11. If the oil pressure reading on the J21867 or equivalent is within specifications, inspect for the following conditions: ^ Plugged or incorrect oil filter and/or malfunctioning oil bypass valve ^ Malfunctioning oil pressure gage or sensor. Repair as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the oil level indicator. 2. Remove the oil level indicator tube bolt. 3. Remove the oil level indicator tube from the engine block. 4. Important: The O-ring seal may be reused if not cut or damaged. Inspect the O-ring seal for cuts or damage. 5. Remove the O-ring seal from the tube, if required. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Page 3800 1. Lubricate the O-ring seal with clean engine oil. 2. Install a NEW O-ring seal onto the oil level indicator tube, if required. 3. Install the oil level indicator tube between the exhaust manifold and engine block. 4. Raise and suitably support the vehicle. 5. Install the oil level indicator tube into the block. The tube must be installed with the collar flush to the block. 6. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the oil level indicator tube bolt Tighten the bolt to 25 Nm (18 ft. lbs.). 8. Install the oil level indicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3805 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3806 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 4.7L (5.0 Qt) With Filter Change ............................................ ................................................................................................................................................. 5.7L (6.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3809 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Grade ............................................................... ............................................................................................................................................................ 5W-30 Below -29° C (-20° F) ................................................................................................................................................. 5W-30 synthetic (preferred) , 0W-30 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3810 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3811 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement (4WD) Removal Procedure The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable. 1. Disconnect the engine oil cooler quick connect fittings. 2. If equipped with a 5.3L or 6.0L engine, perform the following: 1. Open the oil cooler hose clip located on the lower fan shroud. 2. Remove the oil cooler hoses from the clip. 3. Raise and suitably support the vehicle. 4. If equipped with a 8.1L engine, perform the following: 5. Remove the oil cooler hoses from the clip. 6. Raise and suitably support the vehicle. 7. Place jack or utility stands at the rear of the vehicle. 8. If equipped, remove the engine protection shield. 9. If equipped, remove the front differential carrier shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3816 10. Place an adjustable jack under the front differential carrier. 11. Remove the inner axle housing nuts and washers from the bracket. 12. Remove the differential carrier upper mounting bolt and nut. 13. Pivot the differential carrier forward and down on the lower mount bolt while it is being supported by the adjustable jack. 14. Secure the differential carrier to the jack. 15. Remove the differential carrier lower mounting bolt and nut. 16. Lower the jack 4 to 6 inches. 17. If equipped with a 5.3L or 6.0L engine, perform the following: 1. Remove the oil cooler hose bracket bolt (1). 2. Remove the oil cooler hose adapter bolts (2). 3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 4. Inspect the fittings, connectors and cooler hoses for damage or distortion. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3817 18. If equipped with a 8.1L engine, perform the following: 1. Remove the oil cooler hose bracket bolt. 2. Disconnect the quick connect fittings (1) at the engine. 3. Remove the oil cooler hose assembly. Discard the gasket. 4. Inspect the fittings, connectors and cooler hoses for damage or distortion. Installation Procedure 1. If equipped with a 8.1L engine, perform the following: 1. Install the oil cooler hose assembly and a NEW gasket. 2. Connect the quick connect fittings (1) at the engine. 3. Install the oil cooler hose bracket bolt. Tighten the bolt to 50 Nm (37 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: A distinct snap should be heard when assembling the tube ends of the hose assembly to the quick connectors. To ensure the tube is fully inserted into the connector, check by giving the tube a forceful pull. 2. If equipped with a 5.3L or 6.0L engine, perform the following: 1. Install the oil cooler hose assembly and a NEW gasket. 2. Install the oil cooler hose adapter bolts (2). Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the oil cooler hose bracket bolt (1). Tighten the bolt to 25 Nm (18 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3818 3. Raise the jack in order to position the differential carrier. 4. Install the differential carrier lower mounting bolt and nut. Do not tighten the bolt at this time. 5. Pivot the differential carrier up and back on the lower mount bolt while it is being supported by the jack. 6. Install the differential carrier upper mounting bolt and nut. Do not tighten the bolt at this time. 7. Install the inner axle housing washers and nuts to the brackets. ^ The inner axle housing bolts to 100 Nm (75 ft. lbs.). ^ The upper and lower differential carrier bolts to 100 Nm (75 ft. lbs.). 8. Remove the adjustable jack from under the front differential carrier. 9. If equipped, install the front differential carrier shield. 10. If equipped, install the engine protection shield. 11. Remove the jack or utility stands from the rear of the vehicle. 12. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3819 13. If equipped with a 8.1L engine perform the following: 14. Install the oil cooler hoses to the clip. Important: ^ Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. ^ Do not use the plastic cap in order to install the cooler line into the fitting. 15. If equipped with a 5.3L or 6.0L engine, perform the following: 0. Install the oil cooler hoses to the hose clip on the fan shroud. 1. Snap the oil cooler hose clip shut. 16. Connect the engine oil cooler quick connect fittings. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3820 Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Engine Oil Cooler Pipe/Hose Quick Connect Fitting Removal Procedure 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings. 4. Remove the engine oil cooler line from the quick connector fitting at the radiator. Pull the lines straight out from the connectors. 5. Clean all of the components in a suitable solvent, and dry them with compressed air. 6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure 1. Install a new retaining ring into each quick connector fitting. Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3821 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3822 6. Snap the plastic cap onto the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 7. Ensure that the plastic cap is fully seated against the fitting. 8. Ensure that no gap is present between the cap and the fitting. 9. Inspect and fill the engine oil to the proper level. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Filler / Breather Cap > Component Information > Technical Service Bulletins > Customer Interest for Engine Oil Filler / Breather Cap: > 05-06-01-014 > May > 05 > Engine - Oil Leaks In Extreme Cold Temperatures Engine Oil Filler / Breather Cap: Customer Interest Engine - Oil Leaks In Extreme Cold Temperatures Bulletin No.: 05-06-01-014 Date: May 09, 2005 TECHNICAL Subject: Oil Leak Under Extreme Cold Temperatures (-34°C (-30°F) or Colder) (Install Vented Oil Fill Cap) Models: 2004-2005 Buick Rainier 2003-2005 Cadillac Escalade Models 2004-2005 Cadillac CTS-V 2003-2005 Chevrolet Avalanche, Express, Kodiak, Silverado, SSR, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2003-2005 GMC Denali Models, Envoy Models, Savana Van Models, Sierra Models, Topkick, Yukon Models 2004-2005 Pontiac GTO 2005 Pontiac Grand Prix 2003-2005 HUMMER H2 2003 Isuzu NPR/NQR Commercial Models 2003 Work Horse Custom Chassis with 4.8L, 5.3L, 5,7L or 6.0L Gas Engine (VINs V, M, T, P, B, Z, G, S, U, N - RPOs LR4, LH6, LM7, LM4, L33, L59, LS1, LS6, LS2, LQ4, LQ9) Condition Some customers may comment on an engine oil leak under extreme cold temperatures (-34°C (-30°F) or colder). The customer may also comment that there may be some oil seepage out of the engine oil level indicator (dipstick) and/or out of the front or rear crankshaft seals during engine operation only. Cause Under extreme cold temperatures (-34°C (-30°F) or colder) and extended driving conditions, the PCV system may experience a freezing condition and shut off all crankcase gases to pass through the PCV system. This may cause crankcase pressure to rise steadily and, in some cases, this high pressure unseats (pushes out) the oil level indicator from the indicator tube and causes an oil leak during engine operation. Important: If a visual inspection indicates that oil is still leaking from the front or rear crankshaft seals after this bulletin has been performed, then further diagnosis must be performed using the Oil Leak Diagnosis and/or Crankcase Ventilation System Inspection/Diagnosis in SI. Refer to the following SI document number(s) in this bulletin and print a copy for further assistance in diagnosing this condition. ^ Oil Leak Diagnosis (Truck) (SI Document ID #204344) ^ Oil Leak Diagnosis (Car) (SI Document ID #1406822) ^ Crankcase Ventilation System Inspection/Diagnosis (Truck) (SI Document ID #1246823) ^ Crankcase Ventilation System Inspection/Diagnosis (Car) (SI Document ID #954724) Correction Follow the service procedure below for diagnosis and correction of this condition. 1. Inspect for the oil fill dipstick being pushed out of the dipstick tube and that there is engine oil seeping out when the engine is under operation. This condition could be caused by the PCV valve freezing shut. 2. If an icing or freezing condition is found with a PCV valve inspection, then replace the oil fill cap with a vented oil fill cap. 3. Use a new vented oil fill cap, P/N 12589430. A vented oil fill cap will regulate the crankcase pressure between 15 kPa and 18 kPa. This will prevent the over pressurization of the crankcase under the freezing conditions of the PCV system. Once the PCV system thaws out, the crankcase gases will pass through the PCV system and normal crankcase pressure will be restored. 4. Inspect the engine oil level. Start and operate the engine under normal conditions and visually inspect that the engine oil leak has been repaired. If another engine oil leak has been detected, then refer to the above mentioned SI Document Numbers for further assistance in repairing the condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Filler / Breather Cap > Component Information > Technical Service Bulletins > Customer Interest for Engine Oil Filler / Breather Cap: > 05-06-01-014 > May > 05 > Engine - Oil Leaks In Extreme Cold Temperatures > Page 3831 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Filler / Breather Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil Filler / Breather Cap: > 05-06-01-014 > May > 05 > Engine - Oil Leaks In Extreme Cold Temperatures Engine Oil Filler / Breather Cap: All Technical Service Bulletins Engine - Oil Leaks In Extreme Cold Temperatures Bulletin No.: 05-06-01-014 Date: May 09, 2005 TECHNICAL Subject: Oil Leak Under Extreme Cold Temperatures (-34°C (-30°F) or Colder) (Install Vented Oil Fill Cap) Models: 2004-2005 Buick Rainier 2003-2005 Cadillac Escalade Models 2004-2005 Cadillac CTS-V 2003-2005 Chevrolet Avalanche, Express, Kodiak, Silverado, SSR, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2003-2005 GMC Denali Models, Envoy Models, Savana Van Models, Sierra Models, Topkick, Yukon Models 2004-2005 Pontiac GTO 2005 Pontiac Grand Prix 2003-2005 HUMMER H2 2003 Isuzu NPR/NQR Commercial Models 2003 Work Horse Custom Chassis with 4.8L, 5.3L, 5,7L or 6.0L Gas Engine (VINs V, M, T, P, B, Z, G, S, U, N - RPOs LR4, LH6, LM7, LM4, L33, L59, LS1, LS6, LS2, LQ4, LQ9) Condition Some customers may comment on an engine oil leak under extreme cold temperatures (-34°C (-30°F) or colder). The customer may also comment that there may be some oil seepage out of the engine oil level indicator (dipstick) and/or out of the front or rear crankshaft seals during engine operation only. Cause Under extreme cold temperatures (-34°C (-30°F) or colder) and extended driving conditions, the PCV system may experience a freezing condition and shut off all crankcase gases to pass through the PCV system. This may cause crankcase pressure to rise steadily and, in some cases, this high pressure unseats (pushes out) the oil level indicator from the indicator tube and causes an oil leak during engine operation. Important: If a visual inspection indicates that oil is still leaking from the front or rear crankshaft seals after this bulletin has been performed, then further diagnosis must be performed using the Oil Leak Diagnosis and/or Crankcase Ventilation System Inspection/Diagnosis in SI. Refer to the following SI document number(s) in this bulletin and print a copy for further assistance in diagnosing this condition. ^ Oil Leak Diagnosis (Truck) (SI Document ID #204344) ^ Oil Leak Diagnosis (Car) (SI Document ID #1406822) ^ Crankcase Ventilation System Inspection/Diagnosis (Truck) (SI Document ID #1246823) ^ Crankcase Ventilation System Inspection/Diagnosis (Car) (SI Document ID #954724) Correction Follow the service procedure below for diagnosis and correction of this condition. 1. Inspect for the oil fill dipstick being pushed out of the dipstick tube and that there is engine oil seeping out when the engine is under operation. This condition could be caused by the PCV valve freezing shut. 2. If an icing or freezing condition is found with a PCV valve inspection, then replace the oil fill cap with a vented oil fill cap. 3. Use a new vented oil fill cap, P/N 12589430. A vented oil fill cap will regulate the crankcase pressure between 15 kPa and 18 kPa. This will prevent the over pressurization of the crankcase under the freezing conditions of the PCV system. Once the PCV system thaws out, the crankcase gases will pass through the PCV system and normal crankcase pressure will be restored. 4. Inspect the engine oil level. Start and operate the engine under normal conditions and visually inspect that the engine oil leak has been repaired. If another engine oil leak has been detected, then refer to the above mentioned SI Document Numbers for further assistance in repairing the condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Filler / Breather Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil Filler / Breather Cap: > 05-06-01-014 > May > 05 > Engine - Oil Leaks In Extreme Cold Temperatures > Page 3837 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3842 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3843 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil filter. 3. Remove the oil filter adapter (1). Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the oil filter adapter (1). Tighten the adapter to 55 Nm (40 ft. lbs.). 2. Install the oil filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3847 3. Refill the engine oil. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (3). 3. Remove the oil level sensor from the oil pan. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the oil level sensor to the oil pan. Tighten the sensor to 13 Nm (115 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Service and Repair > Page 3851 2. Connect the oil level sensor electrical connector (3). 3. Fill the engine oil. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan M8 Bolts - Oil Pan-to-Engine Block and Oil Pan-to-Front Cover ............................................................................................... 25 Nm (18 ft. lbs.) Oil Pan M6 Bolts Oil Pan-to-Rear Cover ......................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement Oil Pan: Service and Repair Oil Pan Replacement Oil Pan Replacement Removal Procedure 1. If equipped with Four Wheel Drive (4WD), remove the inner axle housing nuts and washers from the bracket. 2. Support the front drive axle with a suitable jack. 3. If equipped with 4WD, remove the differential carrier lower mounting bolt and nut. 4. If equipped with 4WD, remove the differential carrier upper mounting bolt and nut. 5. Lower the front drive axle. 6. Remove the transmission cover bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3860 7. If equipped, remove the oil pan skid plate bolts. 8. Remove the oil pan skid plate. 9. Remove the crossbar bolts. 10. Remove the crossbar. 11. Remove the transmission cover bolt and cover. 12. Drain the engine oil and remove the engine oil filter. 13. Re-install the drain plug and oil filter until snug. 14. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3861 15. Remove the bottom bolt on the left side. 16. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts. 17. Disconnect the oil level sensor electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3862 18. Remove the battery cable channel bolt. 19. Slide the channel pin out of the oil pan tab. 20. Remove the following from the positive battery cable clip: ^ Engine wiring harness clip ^ Positive battery cable clip 21. Remove the engine oil cooler lines from the positive battery cable clip. 22. Remove the positive battery cable clip bolt and clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3863 23. Remove the oil pan bolts. 24. Remove the oil pan. 25. Important: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required. Drill (3) out the oil pan gasket retaining rivets (2), if required. 26. Remove the gasket (1) from the pan. 27. Discard the gasket and rivets. 28. If required, clean and inspect the engine oil pan. Installation Procedure Important: ^ The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane. ^ Do not reuse the oil pan gasket. ^ It is not necessary to rivet the NEW gasket to the oil pan. 1. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 inch) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3864 2. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.8 inch) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface. 3. Important: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket. Pre-assemble the oil pan gasket to the pan. ^ Install the gasket onto the pan. ^ Install the oil pan bolts to the pan and through the gasket. 4. Install the oil pan, gasket and bolts to the engine block. 5. Tighten the oil pan bolts until snug. Do not overtighten. 6. Install the transmission converter cover bolts until snug, if equipped with the 4L80-E automatic transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3865 7. Install the transmission bolt and stud on the right side until snug, If equipped with the 4L60-E automatic transmission. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the bottom bolt on the left side until snug. 1. Tighten the oil pan and oil pan-to-oil pan front cover bolts to 25 Nm (18 ft. lbs.). 2. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 inch lbs.). 3. Tighten the bellhousing, converter cover, and transmission bolts/stud to 50 Nm (37 ft. lbs.). 9. Install the positive battery cable clip and bolt to the oil pan. Tighten the bolt to 9 Nm (80 inch lbs.). 10. Install the engine oil cooler lines to the positive battery cable clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3866 11. Install the following to the positive battery cable clip: ^ Engine wiring harness clip ^ Positive battery cable clip 12. Slide the channel pin in to the oil pan tab. 13. Install the battery cable channel bolt. Tighten the bolt to 12 Nm (106 inch lbs.). 14. Connect the oil level sensor electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3867 15. Install the transmission cover and bolt. Tighten the bolt to 12 Nm (106 inch lbs.). 16. Install the crossbar. 17. Install the crossbar bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). 18. If equipped, install the oil pan skid plate. 19. Install the oil pan skid plate bolts. Tighten the bolts to 20 Nm (15 ft. lbs.). 20. Install the transmission cover bolts Tighten the bolt to 12 Nm (106 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3868 21. Raise the front drive axle into position. 22. If equipped with 4WD, install the differential carrier upper mounting bolt and nut until snug. Do not tighten at this time. 23. If equipped with 4WD, instal the differential carrier lower mounting bolt and nut. Tighten the bolts to 100 Nm (75 ft. lbs.). 24. If equipped with 4WD, install the inner axle housing washers and nuts to the bracket. Tighten the nuts to 100 Nm (75 ft. lbs.). 25. Remove the jack from the front drive axle. 26. Install new engine oil and a new oil filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3869 Oil Pan: Service and Repair Oil Pan Cover Replacement Oil Pan Cover Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil pan cover bolts (1), cover (2), and gasket (3). 3. Discard the gasket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install a new oil pan cover gasket (3), the cover (2) and bolts (1). Tighten the bolts to 12 Nm (106 inch lbs.). 2. Refill the engine oil. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required ^ J41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair > Page 3876 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J41712 or equivalent, install the oil pressure sensor. Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pump, Pump Screen and Deflector Replacement Removal Procedure 1. Remove the oil pan. 2. Remove the engine front cover. 3. Remove the oil pump screen bolt and nuts. 4. Remove the oil pump screen with O-ring seal. 5. Remove the O-ring seal from the pump screen. 6. Discard the O-ring seal. 7. Remove the remaining crankshaft oil deflector nuts. 8. Remove the crankshaft oil deflector. 9. Remove the oil pump bolts. Important: Do not allow dirt or debris to enter the oil pump assembly, cap end as necessary. 10. Remove the oil pump. 11. If required, clean and inspect the oil pump. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Page 3880 1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump. 2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oil pump bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 4. Install the crankshaft oil deflector and nuts until snug. 5. Lubricate a NEW oil pump screen O-ring seal with clean engine oil. 6. Install the NEW O-ring seal onto the oil pump screen. Important: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs. 7. Install the oil pump screen. 8. Install the oil pump screen bolt and nuts. 1. Tighten the bolt to 12 Nm (106 inch lbs.). 2. Tighten the nuts to 25 Nm (18 ft. lbs.). 9. Install the engine front cover. 10. Install the oil pan. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - Hot .................... 41 kPa at 1,000 engine RPM (124 kPa at 2,000 engine RPM) 165 kPa at 4,000 engine RPM (6 psig at 1,000 engine RPM) 18 psig at 2,000 engine RPM (24 psig at 4,000 engine RPM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3885 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Tools Required ^ J21867 Pressure Gage ^ J42907 Oil Pressure Testing Tool 1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10 - 15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following conditions: ^ Oil diluted by water or glycol anti freeze ^ Foamy oil 6. Remove the oil filter and install the J42907. 7. Install J21867 or equivalent to the J42907. 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications (LR4 VIN V) Engine Mechanical Specifications (LM7 VIN T) Engine Mechanical Specifications (L59 VIN Z) Engine Mechanical Specifications (LQ4 VIN U) Engine Mechanical Specifications (LQ9 VIN N). 10. If the engine oil pressure is below specifications, inspect the engine for one or more of the following conditions: ^ Oil pump worn or dirty. ^ Oil pump-to-engine block bolts loose. ^ Oil pump screen loose, plugged, or damaged ^ Oil pump screen O-ring seal missing or damaged ^ Malfunctioning oil pump pressure relief valve ^ Excessive bearing clearance ^ Cracked, porous, or restricted oil galleries ^ Oil gallery plugs missing or incorrectly installed. ^ Broken valve lifters. Repair as necessary. 11. If the oil pressure reading on the J21867 or equivalent is within specifications, inspect for the following conditions: ^ Plugged or incorrect oil filter and/or malfunctioning oil bypass valve ^ Malfunctioning oil pressure gage or sensor. Repair as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair Oil Pressure Regulator Valve: Service and Repair Oil Filter Bypass Valve Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil filter. 3. Remove the oil filter adapter (1). 4. Remove the oil filter bypass valve (2). Installation Procedure 1. Install the oil filter bypass valve (2). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter adapter (1). Tighten the oil filter adapter to 55 Nm (40 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Page 3889 3. Install the oil filter. Tighten the oil filter to 30 Nm (22 ft. lbs.). 4. Refill the engine oil. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3894 Intake Manifold: Specifications Intake Manifold Bolts - First Pass in Sequence ....................................................................................................................................... 5 Nm (44 inch lbs.) Intake Manifold Bolts - Final Pass in Sequence .................................................................................................................................... 10 Nm (89 inch lbs.) Throttle Body Nuts ....................................................................................................................... ......................................................... 10 Nm (89 inch lbs.) Throttle Body Studs .................................. .............................................................................................................................................. 6 Nm (53 inch lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3895 Intake Manifold: Service and Repair Intake Manifold Replacement Removal Procedure 1. Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly. Remove the throttle body. 2. Remove the fuel injectors. 3. Disconnect the following electrical connectors: ^ Manifold Absolute Pressure (MAP) sensor (1) ^ Knock sensor (2) 4. Remove the knock sensor harness electrical connector from the intake manifold. 5. Set the electrical harness aside. 6. If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3896 7. Remove the Positive Crankcase Ventilation (PCV) hose. 8. Remove the MAP sensor (1) from the intake manifold. 9. Remove the Evaporative Emission (EVAP) purge solenoid vent tube by performing the following: 1. Remove the EVAP tube end from the solenoid (1). 2. Remove the EVAP tube end from the vapor pipe (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3897 10. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold. 11. Loosen the intake manifold bolts. 12. Remove the intake manifold. 13. Remove the intake manifold gaskets (1) from the intake manifold. 14. Discard the old intake manifold gaskets. 15. If required, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3898 1. Install NEW intake manifold gaskets (1) to the intake manifold. 2. Install the intake manifold. 3. Apply a 5 mm (0.20 inch) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the intake manifold bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the intake manifold bolts. 1. Tighten the bolts a first pass in sequence to 5 Nm (44 inch lbs.). 2. Tighten the bolts a final pass in sequence to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3899 5. Install the EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold. Tighten the bolt to 10 Nm (89 inch lbs.). 6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2). 7. Important: Lightly coat the MAP sensor seal with clean engine oil before installing. Install the MAP sensor (1) to the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3900 8. Install the PCV hose. 9. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold. 10. Route the electrical harness into position over the engine. 11. Connect the knock sensor harness electrical connector to the intake manifold. 12. Connect the following electrical connectors. ^ MAP sensor (1) ^ Knock sensor (2) 13. Install the fuel injectors. 14. Install the throttle body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement (4.8L, 5.3L, and 6.0L Engines) Tools Required ^ J41479 Crankshaft Rear Oil Seal Installer Removal Procedure 1. Remove the engine flywheel. 2. Remove the crankshaft rear oil seal (1) from the rear cover. Installation Procedure Important: ^ The flywheel spacer (if applicable) must be removed prior to oil seal installation. ^ Do not lubricate the oil seal Inside Diameter (ID) or the crankshaft surface. ^ Do not reuse the crankshaft rear oil seal. 1. Lubricate the Outside Diameter (OD) of the oil seal (1) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface. 2. Lubricate the rear cover oil seal bore with clean engine oil. DO NOT allow oil or other lubricants to contact the crankshaft surface. 3. Install the J41479 tapered cone (2) and bolts onto the rear of the crankshaft. 4. Tighten the bolts until snug. Do not overtighten. 5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear cover bore. 6. Thread the J41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 3905 7. Align the oil seal into the tool (1). 8. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore. 9. Remove the J41479. 10. Install the engine flywheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement Tools Required ^ J41478 Crankshaft Front Oil Seal Installer Removal Procedure 1. Remove the crankshaft balancer. 2. Remove the crankshaft oil seal (1) from the front cover. Installation Procedure Important: ^ Do not lubricate the oil seal sealing surface. ^ Do not reuse the crankshaft oil seal. 1. Lubricate the outer edge of the oil seal (1) with clean engine oil. 2. Lubricate the front cover oil seal bore with clean engine oil. 3. Install the crankshaft front oil seal onto the J41478 guide. 4. Install the J41478 threaded rod (with nut, washer, guide, and oil seal) into the end of the crankshaft. 5. Use the J41478 in order to install the oil seal into the cover bore. 1. Use a wrench and hold the hex on the installer bolt. 2. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 3909 3. Remove the J41478. 4. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore. 6. Install the crankshaft balancer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Tools Required ^ J22794 Spark Plug Port Adapter ^ J38606 Valve Spring Compressor Removal Procedure 1. Remove the rocker arm. 2. Disconnect the spark plug wire at the spark plug. ^ Twist each plug wire boot 1/2 turn. ^ Pull only on the boot in order to remove the wire from the spark plug. 3. Important: Remove the spark plugs from the cylinder head with the engine at room temperature. Loosen the spark plug 1 or 2 turns. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3913 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install the J22794 into the spark plug hole. 7. Attach an air hose to the J22794. 8. Apply compressed air to the J22794 in order to hold the valves in place. 9. Use the J38606 in order to compress the valve spring. 10. Remove the valve stem keys (2). 11. Carefully release the valve spring tension. 12. Remove the J38606. 13. Remove the valve spring cap (3). 14. Remove the valve spring (4). 15. Remove the valve stem oil seal and shim (1, 5) Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3914 1. Clean the cylinder head valve spring seat and/or shim area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valve stem oil seal and shim (1, 5). 4. Install the valve spring (4). 5. Install the valve spring cap (3). 6. Compress the valve spring using the J38606. 7. Install the valve keys. ^ Use grease in order to hold the valve keys in place. ^ Make sure the keys seat properly in the groove of the valve stem. ^ Carefully release the valve spring pressure, making sure the valve keys stay in place. ^ Remove the J38606. ^ Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3915 8. Remove the J22794 from the spark plug port. 9. Notice: Refer to Fastener Notice in Service Precautions. Hand start the spark plug. Tighten the spark plug to 15 Nm (11 ft. lbs.). 10. Install the spark plug wires at the ignition coil. 11. Install the spark plug wire to the spark plug. 12. Inspect the wires for proper installation: ^ Push sideways on each boot in order to check for proper installation. ^ Reinstall any loose boot. 13. Install the rocker arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (3). 3. Remove the oil level sensor from the oil pan. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the oil level sensor to the oil pan. Tighten the sensor to 13 Nm (115 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair > Page 3920 2. Connect the oil level sensor electrical connector (3). 3. Fill the engine oil. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required ^ J41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 3930 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J41712 or equivalent, install the oil pressure sensor. Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Timing Chain and Sprockets Replacement Tools Required ^ J8433 Two Jaw Puller ^ J41816-2 Crankshaft End Protector ^ J41558 Crankshaft Sprocket Remover ^ J41665 Crankshaft Balancer and Sprocket Installer Removal Procedure 1. Remove the oil pump. 2. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned. Notice: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 3. Remove the camshaft sprocket bolts. 4. Remove the camshaft sprocket and timing chain. 5. Use the J8433, the J41816-2 and the J41558 in order to remove the crankshaft sprocket. 6. Remove the crankshaft sprocket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3935 7. Remove the crankshaft sprocket key, if required. 8. If required, clean and inspect the timing chain and sprockets. Installation Procedure 1. Install the key into the crankshaft keyway, if previously removed. 2. Tap the key (1) into the keyway until both ends of the key bottom onto the crankshaft. 3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3936 4. Use the J41665 in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange. 5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position. 6. Important: ^ Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. ^ The sprocket teeth and timing chain must mesh. ^ The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Locate the camshaft sprocket alignment mark in the 6 o'clock position. Install the camshaft sprocket and timing chain. 7. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the camshaft sprocket bolts. Tighten the bolts to 35 Nm (26 ft. lbs.). 9. Install the oil pump. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Bolts .................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3940 Timing Cover: Service and Repair Engine Front Cover Replacement Tools Required ^ J41476 Front and Rear Cover Alignment Tool Removal Procedure 1. Remove the water pump. 2. Remove the crankshaft balancer. 3. Remove the oil pan-to-front cover bolts (1). 4. Remove the front cover bolts. 5. Remove the front cover and gasket. 6. Discard the front cover gasket. 7. If required, clean and inspect the engine front cover. Installation Procedure Important: ^ Do not reuse the crankshaft oil seal or front cover gasket. ^ Do not apply any type of sealant to the front cover gasket, unless specified. ^ The special tool in this procedure is used to properly center the front crankshaft front oil seal. All gasket surfaces should be free of oil or other foreign material during assembly. - The crankshaft front oil seal MUST be centered in relation to the crankshaft. - An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3941 1. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 inch) long to the oil pan to engine block junction. 2. Install the front cover gasket and cover. 3. Install the front cover bolts until snug. Do not overtighten. 4. Install the oil pan-to-front cover bolts (1) until snug. Do not over tighten. 5. Install J41476 to the front cover. 6. Align the tapered legs of the J41476 with the machined alignment surfaces on the front cover. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the crankshaft balancer bolt until snug. Do not overtighten. 1. Tighten the oil pan to front cover bolts to 25 Nm (18 ft. lbs.). 2. Tighten the engine front cover bolts to 25 Nm (18 ft. lbs.). 8. Remove the J41476. 9. Install a NEW crankshaft front oil seal. 10. Install the water pump. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................385-425 kPa (55-62 psi) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3948 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3949 Steps 1-4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3950 Steps 5-13 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3963 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3969 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3970 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3971 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3977 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. Refer to Fuel Pressure Gage Installation and Removal. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. .........................................................1,000 ohms per ft Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 3981 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 3982 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: IMPORTANT: The Melco(R) spark plug wires MUST be used only with the Melco(R) coils and bracket, like wise the Delphi(R) spark plug wires MUST be used only with Delphi(R) coils and bracket. The components are NOT interchangeable. 4. The Melco(R) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(R) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. 6. The Melco(R) (1) ignition coil is a square design. 7. The Delphi(R) (2) ignition coil is a round design. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 3983 8. The Melco(R) ignition coil bracket (1) is a square design. 9. The Delphi(R) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ............................................ 1.02 mm (0.04 inches) Spark Plug Torque ............................................. ................................................................................................................................... 15 Nm (11 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3987 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................... AC 25171803 (NGK 12567759) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3988 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3989 - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3990 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3991 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Spark plug gap: 1.016 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. - Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 5. Install the spark plug wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3995 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Check the compression again and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt First Pass ............................................................................................................................................. .................................................. 15 Nm (11 ft. lbs.) Final Pass ........................................................... ................................................................................................................................... 30 Nm (22 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3999 Water Pump: Service and Repair Water Pump Replacement (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator hose clips. 7. Reposition the inlet hose clamp at the water pump. 8. Remove the inlet hose from the water pump. 9. Remove the fan blade. 10. Remove the accessory drive belt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4000 11. Reposition the outlet hose clamp at the water pump. 12. Remove the outlet hose from the water pump. 13. Reposition the surge tank outlet hose clamp at the water pump. 14. Remove the surge tank outlet hose from the water pump. 15. Reposition the heater inlet hose clamp at the water pump. 16. Remove the heater inlet hose from the water pump. 17. Remove the water pump bolts. 18. Remove the water pump and gaskets. 19. Discard the water pump gaskets. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4001 Important: All gaskets surfaces are to be free of oil or other foreign material during assembly. 1. Install the water pump and NEW gaskets. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the water pump bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). 2. Tighten the bolts a final pass to 30 Nm (22 ft. lbs.). 3. Install the heater inlet hose to the water pump. 4. Position the heater inlet hose clamp at the water pump. 5. Install the surge tank outlet hose to the water pump. 6. Position the surge tank outlet hose clamp at the water pump. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4002 7. Install the outlet hose to the water pump. 8. Position the outlet hose clamp at the water pump. 9. Install the accessory drive belt. 10. Install the fan blade. 11. Install the inlet hose to the water pump. 12. Position the inlet hose clamp at the water pump. 13. Install the engine vent inlet hose to the radiator hose clips. 14. If necessary, install the engine sight shield. 15. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 16. Install the radiator inlet hose clip to the outlet duct. 17. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4003 Tighten the clamps to 4 Nm (35 inch lbs.). 18. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement Cooling System Air Bleeder Pipe / Hose: Service and Repair Coolant Air Bleed Pipe Assembly Replacement Coolant Air Bleed Pipe Assembly Replacement (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Remove the coolant air bleed pipe bolts/studs (1). 3. Remove the coolant air bleed pipe (2) with gaskets (3). 4. Remove the coolant air bleed pipe cover bolts (1) and covers (2). 5. Remove the gaskets from the coolant air bleed pipe and covers. 6. Discard the gaskets. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement > Page 4009 7. Remove the coolant air bleed hose (1) from the pipe (2). Installation Procedure 1. Install the coolant air bleed hose (1) onto the pipe (2). 2. Important: Install the gaskets properly onto the pipe and covers. Position the O-ring seal onto the nipple portion of the pipe. Install the gaskets onto the coolant air bleed pipe and covers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement > Page 4010 3. Install the coolant air bleed pipe (2) and gaskets (3) onto the cylinder heads. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the coolant air bleed pipe bolts/studs (1). Tighten the bolts/studs to 12 Nm (106 inch lbs.). 5. Install the coolant air bleed pipe covers (2) and bolts (1). Tighten the bolts to 12 Nm (106 inch lbs.). 6. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement > Page 4011 Cooling System Air Bleeder Pipe / Hose: Service and Repair Coolant Air Bleed Hose Replacement Coolant Air Bleed Hose Replacement (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Reposition the coolant air bleed hose clamp at the throttle body. 2. Remove the coolant air bleed hose from the throttle body. 3. Reposition the coolant air bleed hose clamp at the pipe. 4. Remove the coolant air bleed hose (1) from the pipe (2). Installation Procedure 1. Install the coolant air bleed hose (1) to the pipe (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement > Page 4012 2. Position the coolant air bleed hose clamp at the pipe. 3. Install the coolant air bleed hose to the throttle body. 4. Position the coolant air bleed hose clamp at the throttle body. 5. Add engine coolant, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4017 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4018 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4019 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4020 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM CAPACITY AUTOMATIC WITH FRONT A/C .......................................................................................................................................... 15.2 quarts (14.4 liters) With Engine Driven Cooling Fan AUTOMATIC WITH FRONT A/C ......................................................................................................................................... 16.8 quarts (15.9 liters) With Electric Cooling Fan NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 4023 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement Coolant Reservoir: Service and Repair Surge Tank Replacement Surge Tank Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Remove the surge tank overflow hose from the surge tank. 4. Disconnect the coolant level sensor electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 4028 5. Reposition the surge tank inlet and outlet hose clamps. 6. If equipped with a 4.3 L, 4.8 L, 5.3 L, 6.0 L, or 8.1 L engine, remove the surge tank inlet (1) and outlet (2) hoses from the surge tank. 7. Reposition the surge tank inlet hose clamp from the surge tank. 8. Remove the surge tank inlet hose (1) from the surge tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 4029 9. Reposition the surge tank outlet hose clamp from the surge tank. 10. Remove the surge tank outlet hose (2) from the surge tank. 11. Remove the bolt from the surge tank. 12. Remove the nut from the surge tank. 13. Remove the surge tank. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 4030 1. Install the surge tank. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt to the surge tank. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the nut to the surge tank. Tighten the nut to 9 Nm (80 inch lbs.). 4. Install the surge tank outlet hose (2) to the surge tank. 5. Position the surge tank outlet hose clamp to the surge tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 4031 6. Install the surge tank inlet hose (1) to the surge tank. 7. Position the surge tank inlet hose clamp to the surge tank. 8. Connect the coolant level sensor electrical connector (3). 9. Install the surge tank overflow hose. 10. Install the air cleaner assembly. 11. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 4032 Coolant Reservoir: Service and Repair Surge Tank Hose/Pipe Replacement - Inlet Surge Tank Hose/Pipe Replacement - Inlet Removal Procedure 1. Drain the cooling system. 2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet hose from the radiator. 4. Reposition the surge tank inlet hose clamp from the surge tank. 5. Remove the surge tank inlet hose (1) from the surge tank. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 4033 1. Install the surge tank inlet hose (1) to the surge tank. 2. Position the surge tank inlet hose clamp to the surge tank. 3. Install the surge tank inlet hose to the radiator. 4. Position the surge tank inlet hose clamp to the radiator. 5. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 4034 Coolant Reservoir: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Drain the cooling system. 2. Reposition the vent inlet hose clamp from the radiator. 3. Remove the vent inlet hose from the radiator. 4. Reposition the vent inlet hose clamp from the surge tank. 5. Remove the vent inlet hose from the surge tank. Installation Procedure 1. Install the vent inlet hose to the surge tank. 2. Reposition the vent inlet hose clamp to the surge tank. 3. Install the vent inlet hose to the radiator. 4. Reposition the vent inlet hose clamp to the radiator. 5. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair Radiator Cooling Fan Motor: Service and Repair Cooling Fan Motor Replacement - Electric Removal Procedure 1. Remove the cooling blade(s). 2. Remove the cooling fan motor bolts. 3. Remove the cooling fan motor(s). Installation Procedure 1. Install the cooling fan motor(s). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the cooling fan motor bolts. Tighten the bolts to xx Nm (xx ft. lbs.). 3. Install the cooling fan blade(s). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations COOLING FAN RELAYS LF Of Engine Compartment Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 4042 Location View Application Table The Cooling Fan 1, Cooling Fan 2, Cooling Fan 3, relays are located in the Fuse Block Underhood - Cooling Fan (10 Series). The Fuse Block - Underhood - Cooling Fan (10 Series) is located in the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Service and Repair Fan Clutch: Service and Repair Fan Clutch Replacement Tools Required ^ J46406 Fan Clutch Remover and Installer Removal Procedure 1. Remove the upper fan shroud. 2. Install the J46406 to the fan clutch. 3. Remove the fan hub nut from the water pump in a counterclockwise rotation. 4. Remove the fan clutch bolts from the rear of the fan blade. 5. Separate the fan clutch from the fan blade. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Service and Repair > Page 4046 1. Install the fan clutch bolts from the rear of the fan blade. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the fan clutch bolts. Tighten the bolts to 23 Nm (17 ft. lbs.). 3. Install the fan assembly. 4. Install the J46406 to the fan clutch. Tighten the nut clockwise to 56 Nm (41 ft. lbs.). 5. Install the upper fan shroud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4051 Left Side Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4052 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4053 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4054 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper Fan Shroud: Service and Repair Fan Shroud - Upper W/RPO M74 Fan Shroud Replacement - Upper (w/RPO M74) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor. 3. Remove the air cleaner outlet duct. 4. Remove the A/C line retainer from the fan shroud. 5. Remove the engine harness clip from the powertrain control module (PCM) cover. 6. Remove the Transmission Control Module (TCM) cover bolts. 7. Remove TCM cover from the fan shroud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4059 8. Loosen the TCM electrical connector bolts. 9. Disconnect the TCM electrical connectors (1). 10. Remove the TCM and cover. 11. Remove the fan shroud retainers. 12. Remove the fan shroud bolts 13. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4060 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fan shroud bolts. Tighten the bolts to 9 Nm (80 inch lbs.). 3. Install the fan shroud retainers. 4. Connect the TCM electrical connectors (1). 5. Install the TCM and cover. 6. Tighten the TCM electrical connector bolts. Tighten the bolts to 8 Nm (71 inch lbs.). 7. Install the TCM cover to the fan shroud. 8. Install the TCM cover bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4061 9. Install the engine harness clip to the PCM cover. 10. Install the A/C line retainer to the fan shroud. 11. Install the air cleaner outlet duct. 12. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp to 4 Nm (35 inch lbs.). 13. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten the clamp to 4 Nm (35 inch lbs.). W/O RPO M74 Fan Shroud Replacement - Upper (w/o RPO M74) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor. 3. Remove the air cleaner outlet duct. 4. If equipped remove the throttle body heater hose retainer from the fan shroud. 5. If equipped remove the inlet radiator hose retainer from the fan shroud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4062 6. Remove the fan shroud retainers. 7. Remove the fan shroud bolts 8. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fan shroud bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4063 3. Install the fan shroud retainers. 4. If equipped install the inlet radiator hose retainer to the fan shroud 5. If equipped install the throttle body heater hose retainer to the fan shroud. 6. Install the air cleaner outlet duct. 7. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp to 4 Nm (35 inch lbs.). 8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten the clamp to 4 Nm (35 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4064 Fan Shroud: Service and Repair Fan Shroud - Lower Fan Shroud Replacement - Lower Removal Procedure 1. Remove the cooling fan. 2. If equipped with engine oil cooler, remove the oil cooler hose clip from the lower fan shroud. 3. Lift the lower fan shroud up in order to disengage the fan shroud from the retaining clips on the radiator. Installation Procedure 1. Install the lower fan shroud to the retaining clips on the radiator and firmly push down. 2. If equipped with the engine oil cooler, Install the oil cooler hose clip to the lower fan shroud. 3. Install the cooling fan. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 4069 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 4070 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT (HEAT ONLY) REMOVAL PROCEDURE 1. Remove the heater/vent module. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the heater core cover screws. 3. Remove the heater core cover. 4. Remove the heater core. INSTALLATION PROCEDURE 1. Install the heater core. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 4073 2. Install the heater core cover. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install heater core cover screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 4. Install the heater/vent module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 4074 Heater Core: Service and Repair Heater Core Replacement - Delphi HEATER CORE REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 4075 1. Install the heater core (2) to the HVAC module assembly (3). 2. Install the heater core cowl gasket (1) to the heater core (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 4076 Heater Core: Service and Repair Heater Core Replacement - Visteon HEATER CORE REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (1) from the HVAC module assembly (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 4077 INSTALLATION PROCEDURE 1. Install the heater core (1) to the HVAC module assembly (2). 2. Install the heater core cowl gasket (1) to the HVAC module assembly (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 4078 Tighten the screws to 2 Nm (18 lb in). 5. Install the HVAC module assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Using the J 43181 disconnect the heater hose from the heater core inlet. 3.1. Install the J 43181 to the heater core pipe. 3.2. Close the tool around the heater core pipe. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 4. Reposition the inlet heater hose clamp from the engine. 5. Remove the inlet heater hose from the engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 4083 6. Remove the inlet heater hose mounting bolt. 7. Remove the inlet heater hose from the engine. 8. Remove the inlet heater hose. INSTALLATION PROCEDURE 1. Install the inlet heater hose. 2. Install the inlet heater hose to the engine. 3. Reposition the inlet heater hose clamp to the engine. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the inlet heater hose mounting bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 4084 5. Install the inlet heater hose to the engine. 6. Connect the heater hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 7. Install the air intake tube. 8. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 4085 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core outlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the outlet heater hose from the engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 4086 6. Remove the outlet heater hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. 2. Install the outlet heater hose to the engine. 3. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the radiator drain cock. Installation Procedure 1. Install the radiator drain cock. 2. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing Tools required ^ J24460-01 Cooling System Pressure Tester ^ J42401 Radiator Cap / Surge Tank Test Adapter Pressure Cap Testing 1. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J24460-01 (1) with J42401 (2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: ^ Pressure release when the J24460-01 exceeds the pressure rating of the pressure cap. ^ Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: ^ The pressure cap does not release pressure which exceeds the rated pressure of the cap. ^ The pressure cap does not hold the rated pressure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet hose. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator inlet hose clips. 7. Reposition the inlet hose clamp at the radiator. 8. Remove the inlet hose clip from the fan shroud. 9. Remove the inlet hose (1) from the radiator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 4098 10. Reposition the inlet hose clamp at the water pump. 11. Remove the inlet hose from the water pump. Installation Procedure 1. Install the inlet hose to the water pump. 2. Position the inlet hose clamp at the water pump. 3. Install the inlet hose (1) to the radiator. 4. Position the inlet hose clamp at the radiator. 5. Install the inlet hose clip to the fan shroud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 4099 6. Install the radiator vent inlet hose to the radiator inlet hose clips. 7. If necessary, install the engine sight shield. 8. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 9. Install the radiator inlet hose clip to the outlet duct. 10. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Tighten the clamps to 4 Nm (35 inch lbs.). 11. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 4100 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the outlet hose clamp at the water pump. 6. Remove the outlet hose from the water pump. 7. Reposition the outlet hose clamp at the radiator. 8. Remove the outlet hose (6) from the radiator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 4101 1. Install the outlet hose (6) to the radiator. 2. Position the outlet hose clamp at the radiator. 3. Install the outlet hose to the water pump. 4. Position the outlet hose clamp at the water pump. 5. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. 7. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Tighten the clamps to 4 Nm (35 inch lbs.). 8. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations COOLING FAN RELAYS LF Of Engine Compartment Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 4106 Location View Application Table The Cooling Fan 1, Cooling Fan 2, Cooling Fan 3, relays are located in the Fuse Block Underhood - Cooling Fan (10 Series). The Fuse Block - Underhood - Cooling Fan (10 Series) is located in the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4112 Left Side Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4113 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4114 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4115 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications 6.6L Thermostat Full Open Temperature ....................................................................................................................................... 110 degrees C (230 degrees F) All Other Engines J24731-188 tempil stick melts at 87° C (188° F). The thermostat should begin to open. J24731-206 tempil stick melts at 97° C (206° F). The thermostat should be fully open. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair Thermostat Housing: Service and Repair Thermostat Housing Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure Important: The thermostat is not serviceable separately. The water pump inlet and thermostat must be replaced as an assembly. 1. Remove the radiator outlet hose. 2. Remove the water pump inlet bolts. 3. Remove the water pump inlet and thermostat from the water pump. Installation Procedure 1. Install the thermostat and thermostat housing to the water pump. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the thermostat housing bolts. Tighten the bolts to 15 Nm (11 ft. lbs.). 3. Install the radiator outlet hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt First Pass ............................................................................................................................................. .................................................. 15 Nm (11 ft. lbs.) Final Pass ........................................................... ................................................................................................................................... 30 Nm (22 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4125 Water Pump: Service and Repair Water Pump Replacement (4.8L, 5.3L, and 6.0L) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator hose clips. 7. Reposition the inlet hose clamp at the water pump. 8. Remove the inlet hose from the water pump. 9. Remove the fan blade. 10. Remove the accessory drive belt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4126 11. Reposition the outlet hose clamp at the water pump. 12. Remove the outlet hose from the water pump. 13. Reposition the surge tank outlet hose clamp at the water pump. 14. Remove the surge tank outlet hose from the water pump. 15. Reposition the heater inlet hose clamp at the water pump. 16. Remove the heater inlet hose from the water pump. 17. Remove the water pump bolts. 18. Remove the water pump and gaskets. 19. Discard the water pump gaskets. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4127 Important: All gaskets surfaces are to be free of oil or other foreign material during assembly. 1. Install the water pump and NEW gaskets. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the water pump bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). 2. Tighten the bolts a final pass to 30 Nm (22 ft. lbs.). 3. Install the heater inlet hose to the water pump. 4. Position the heater inlet hose clamp at the water pump. 5. Install the surge tank outlet hose to the water pump. 6. Position the surge tank outlet hose clamp at the water pump. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4128 7. Install the outlet hose to the water pump. 8. Position the outlet hose clamp at the water pump. 9. Install the accessory drive belt. 10. Install the fan blade. 11. Install the inlet hose to the water pump. 12. Position the inlet hose clamp at the water pump. 13. Install the engine vent inlet hose to the radiator hose clips. 14. If necessary, install the engine sight shield. 15. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 16. Install the radiator inlet hose clip to the outlet duct. 17. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4129 Tighten the clamps to 4 Nm (35 inch lbs.). 18. Fill the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Precautions Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4135 Catalytic Converter: Service and Repair Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) Removal Procedure 1. Raise and suitably support the vehicle. 2. If equipped, unclip the oxygen sensor connection from the floor reinforcement. 3. Disconnect the oxygen sensor electrical connector. 4. Remove the oxygen sensor clips from the frame. 5. Disconnect the connector position assurance (CPA) retainers. 6. Disconnect the oxygen sensor electrical connectors. 7. Unclip the oxygen sensors electrical connectors from the following: ^ Hose clip ^ Transmission crossmember 8. Disconnect the CPA retainers. 9. Disconnect the oxygen sensor electrical connectors (1, 2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4136 10. Remove the left exhaust manifold pipe nuts. 11. Remove the right exhaust manifold pipe nuts. 12. Remove the exhaust muffler nuts. 13. Remove the catalytic converter. 14. If necessary, remove the oxygen sensors. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4137 1. If necessary, install the oxygen sensors. 1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. 2. Install the oxygen sensors. Tighten the sensors to 42 Nm (31 ft. lbs.). 2. Install the catalytic convertor. 3. Install NEW exhaust manifold pipe seals to the exhaust manifolds. 4. Install the right exhaust manifold pipe nuts until snug. 5. Install the left exhaust manifold pipe nuts until snug. 6. Tighten the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 7. Install the exhaust muffler nuts. Tighten the nuts to 40 Nm (30 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4138 8. Connect the oxygen sensor electrical connectors (1, 2). 9. Connect the CPA retainers. 10. Clip the oxygen sensors electrical connectors to the following: ^ Hose clip ^ Transmission crossmember 11. Connect the oxygen sensor electrical connectors. 12. Connect the CPA retainers. 13. Install the clip around the engine harness and the oxygen sensor pigtail. 14. Connect the oxygen sensor electrical connector. 15. If equipped, clip the oxygen sensor connection to the floor reinforcement. 16. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold - Left Tighten the bolts a first pass ................................................................................................................ ................................................... 15 Nm (11 ft. lbs.) Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the bolts a final pass ............................................................................................................... ................................................... 25 Nm (18 ft. lbs.) Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Exhaust Manifold - Right Tighten the bolts a first pass ................................................................................................................ ................................................... 15 Nm (11 ft. lbs.) Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the bolts a final pass ............................................................................................................... ................................................... 25 Nm (18 ft. lbs.) Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Exhaust Manifold Replacement - Left (4.8L, 5.3L, and 6.0L Engine) Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust manifold pipe nuts. 3. Lower the vehicle. 4. Remove the spark plugs. 5. Remove the exhaust manifold bolts, manifold, and gasket. 6. Discard the gasket. 7. Remove the heat shield bolts (3), and shield (2) from the exhaust manifold (1), if necessary. 8. Clean and inspect the exhaust manifold. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 4144 1. Install the heat shield (2), and bolts (3) to the exhaust manifold (1), if necessary. Tighten the bolts to 9 Nm (80 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Apply a 5 mm (0.2 inch) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. Important: o Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. ^ The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Important: Do not apply sealant to the first three threads of the bolt. 3. Install the exhaust manifold, NEW gasket and bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head. 5. Install the spark plugs. 6. Raise the vehicle. 7. Install the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (37 ft. lbs.). 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 4145 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Exhaust Manifold Replacement - Right (4.8L, 5.3L, and 6.0L Engines) 1. Raise and suitably support the vehicle. 2. Remove the exhaust manifold pipe nuts. 3. Lower the vehicle. 4. Remove the spark plugs. 5. Remove the exhaust manifold bolts, manifold, and gasket. 6. Discard the gasket. 7. Remove the heat shield bolts (1), and shield (2) from the exhaust manifold (1), if necessary. 8. Clean and inspect the exhaust manifold. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 4146 1. Install the heat shield (2), and bolts (1) to the exhaust manifold (1), if necessary. Tighten the bolts to 9 Nm (80 inch lbs.). 2. Apply a 5 mm (0.2 inch) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. Important: Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. ^ The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Important: Do not apply sealant to the first three threads of the bolt. 3. Install the exhaust manifold, NEW gasket and bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head. 5. Install the spark plugs. 6. Raise the vehicle. 7. Install the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (37 ft. lbs.). 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling Heat Shield: Customer Interest Exhaust System - Popping/Snapping Noise When Hot/Idling Bulletin No.: 03-06-05-008D Date: March 05, 2007 TECHNICAL Subject: Exhaust Popping/Snapping Noise When Vehicle is Hot, at Idle, or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Suburban, Tahoe, Silverado, Silverado HD 2007 Chevrolet Silverado Classic, Silverado HD Classic 2002-2006 GMC Sierra, Sierra HD , Yukon, Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic, Sierra HD Classic 2003-2006 HUMMER H2 with 4.8L, 5.3L, 6.0L or 8.1L Gasoline Engine (VINs V, B, T, Z, N, V, G - RPOs LR4, L33, LM7, L59, LQ9, LQ4, L18) Supercede: This bulletin is being revised to add the 2006 and 2007 (Classic Only) model years and the 5.3L (L33) engine. Please discard Corporate Bulletin Number 03-06-05-008C (Section 06 Engine/Propulsion System). Condition Some customers may comment on a popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause As the exhaust system warms and cools, the muffler and the muffler heat shield expand and contract at different rates and may cause a popping and/or snapping noise. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Correction Follow the service procedure below to correct this condition. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges could result in serious personal injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4155 Remove the nuts securing the muffler to the catalytic converter. On 6.0L and 8.1L equipped vehicles only, loosen the exhaust pipe clamp. Do not use oil base lubricants on the rubber exhaust hangers. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers. Pry the exhaust hangers free from the exhaust pipe hanger rods. It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield. Reposition the muffler to gain access to the muffler heat shield. Use extreme caution not to damage the muffler when removing the heat shield from the muffler. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above. Remove the heat shield from the muffler. Hammer flush the remaining heat shield to the muffler. The new heat shield should not come in contact with the remaining muffler heat shield. The new heat shield should not come in contact with the horizontal lock seam on the muffler. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4156 Install the new heat shield (see parts list below) onto the muffler as shown above. Install three straps, P/N 10391259, so that the strap screw head will be located on top of the muffler. Tighten Tighten the strap screw to 4 N.m (35 lb in). Cut off the excess strap material and bend the strap over the strap screw head as indicated above. Remove the exhaust pipe clamp. ONLY 6.0L and 8.1L equipped vehicles require a new exhaust pipe clamp, P/N 15103174. On 6.0L and 8.1L equipped vehicles only, install a new exhaust pipe clamp, P/N 15103174, on the exhaust pipe. Reposition the muffler in the correct position. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter. Install the nuts securing the muffler to the catalytic converter, but DO NOT tighten at this time. Apply a soapy solution to the following areas in order to ease the installation of the hangers. The inner diameter of the exhaust pipe hanger The exhaust pipe hanger rod Press the exhaust pipe hangers over the exhaust pipe hanger rods. Tighten Tighten the muffler nuts by hand until each contacts the metal flange. Tighten the muffler nuts to 45 N.m (33 lb ft). On 6.0L and 8.1L equipped vehicles only, tighten the exhaust clamp to 50 N.m (36 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4157 Lower the vehicle. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4158 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling Heat Shield: All Technical Service Bulletins Exhaust System - Popping/Snapping Noise When Hot/Idling Bulletin No.: 03-06-05-008D Date: March 05, 2007 TECHNICAL Subject: Exhaust Popping/Snapping Noise When Vehicle is Hot, at Idle, or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Suburban, Tahoe, Silverado, Silverado HD 2007 Chevrolet Silverado Classic, Silverado HD Classic 2002-2006 GMC Sierra, Sierra HD , Yukon, Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic, Sierra HD Classic 2003-2006 HUMMER H2 with 4.8L, 5.3L, 6.0L or 8.1L Gasoline Engine (VINs V, B, T, Z, N, V, G - RPOs LR4, L33, LM7, L59, LQ9, LQ4, L18) Supercede: This bulletin is being revised to add the 2006 and 2007 (Classic Only) model years and the 5.3L (L33) engine. Please discard Corporate Bulletin Number 03-06-05-008C (Section 06 Engine/Propulsion System). Condition Some customers may comment on a popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause As the exhaust system warms and cools, the muffler and the muffler heat shield expand and contract at different rates and may cause a popping and/or snapping noise. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Correction Follow the service procedure below to correct this condition. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges could result in serious personal injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4164 Remove the nuts securing the muffler to the catalytic converter. On 6.0L and 8.1L equipped vehicles only, loosen the exhaust pipe clamp. Do not use oil base lubricants on the rubber exhaust hangers. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers. Pry the exhaust hangers free from the exhaust pipe hanger rods. It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield. Reposition the muffler to gain access to the muffler heat shield. Use extreme caution not to damage the muffler when removing the heat shield from the muffler. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above. Remove the heat shield from the muffler. Hammer flush the remaining heat shield to the muffler. The new heat shield should not come in contact with the remaining muffler heat shield. The new heat shield should not come in contact with the horizontal lock seam on the muffler. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4165 Install the new heat shield (see parts list below) onto the muffler as shown above. Install three straps, P/N 10391259, so that the strap screw head will be located on top of the muffler. Tighten Tighten the strap screw to 4 N.m (35 lb in). Cut off the excess strap material and bend the strap over the strap screw head as indicated above. Remove the exhaust pipe clamp. ONLY 6.0L and 8.1L equipped vehicles require a new exhaust pipe clamp, P/N 15103174. On 6.0L and 8.1L equipped vehicles only, install a new exhaust pipe clamp, P/N 15103174, on the exhaust pipe. Reposition the muffler in the correct position. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter. Install the nuts securing the muffler to the catalytic converter, but DO NOT tighten at this time. Apply a soapy solution to the following areas in order to ease the installation of the hangers. The inner diameter of the exhaust pipe hanger The exhaust pipe hanger rod Press the exhaust pipe hangers over the exhaust pipe hanger rods. Tighten Tighten the muffler nuts by hand until each contacts the metal flange. Tighten the muffler nuts to 45 N.m (33 lb ft). On 6.0L and 8.1L equipped vehicles only, tighten the exhaust clamp to 50 N.m (36 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4166 Lower the vehicle. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4167 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement Heat Shield: Service and Repair Floor Panel Heat Shield Replacement Floor Panel Heat Shield Replacement Removal Procedure 1. Remove the exhaust manifold pipe, if necessary. 2. Remove the catalytic converter, if necessary. 3. Remove the exhaust front heat shield nuts. 4. Remove the exhaust front heat shield from the studs. 5. If vehicle is a regular cab pick-up truck, remove the exhaust heat shield nuts. 6. Remove the exhaust front heat shield (1) and/or the exhaust heat shield (2) from the studs. 7. If vehicle is a extended cab pick-up truck, remove the exhaust heat shield nuts. 8. Remove the exhaust heat shield (1, 2) from the studs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 4170 9. If vehicle is a crew cab pick-up truck, remove the exhaust heat shield nuts. 10. Remove the exhaust heat shields from the studs. Installation Procedure 1. If vehicle is a crew cab pick-up truck, install the exhaust heat shields to the studs. 2. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. If vehicle is a extended cab pick-up truck, install the exhaust heat shield (1, 2) to the studs. 4. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 4171 5. If vehicle is a regular cab pick-up truck, install the exhaust front heat shield (1) and/or the exhaust heat shield (2) to the studs. 6. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). 7. Install the exhaust front heat shield to the studs. 8. Install the exhaust front heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). 9. Install the catalytic converter, if necessary. 10. Install the exhaust manifold pipe, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 4172 Heat Shield: Service and Repair Exhaust Heat Shield Replacement Exhaust Heat Shield Replacement Removal Procedure 1. Remove the exhaust muffler. 2. Remove the spare tire hoist. 3. If equipped with a 6 1/2 ft. box, remove the exhaust heat shield bolts. 4. Remove the exhaust heat shield. 5. If equipped with a 8 ft. box, remove the exhaust heat shield bolts. 6. Remove the exhaust heat shield. Installation Procedure 1. if equipped with a 8 ft. box, install the exhaust heat shield. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust heat shield bolts. Tighten the exhaust heat shield bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 4173 3. if equipped with a 6 1/2 ft. box, install the exhaust heat shield. 4. Install the exhaust heat shield bolts. Tighten the exhaust heat shield bolts to 9 Nm (80 inch lbs.). 5. Install the spare tire hoist. 6. Install the exhaust muffler. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 4174 Heat Shield: Service and Repair Exhaust Heat Shield Replacement - Dash Panel Exhaust Heat Shield Replacement - Dash Panel Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust heat shield nuts. 3. Remove the exhaust heat shield (1, 3) from the dash panel studs. 4. If removing the heat shield (3), remove the shield out thru the passenger side wheelwell. Installation Procedure 1. If installing the heat shield (3), install the shield thru the passenger side wheelwell. 2. Install the exhaust heat shield (1, 3) to the dash panel studs. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the exhaust heat shield nuts. Tighten the nuts to 9 Nm (80 inch lbs.). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler Replacement (4.3L, 4.8L, and 5.3L Engines) Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust muffler nuts. 3. Apply lubricant to the exhaust insulators in order to aid in removal. 4. Remove the muffler brackets from the insulators. 5. Remove the exhaust muffler. Installation Procedure 1. Apply lubricant to the exhaust insulators in order to aid in installation. 2. Install the muffler to the insulators. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 4178 3. Install the exhaust muffler nuts. Tighten the nuts to 40 Nm (30 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Remove the clip from around the engine harness and the oxygen sensor pigtail. 2. Disconnect the connector position assurance (CPA) retainer. 3. Disconnect the forward oxygen sensor electrical connector. 3. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Unclip the oxygen sensor electrical connector from the hose clip. 2. Disconnect the CPA retainer. 3. Disconnect the oxygen sensor electrical connector (1). 4. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Disconnect the CPA retainer. 2. Disconnect the oxygen sensor electrical connector (1). 5. Support the catalytic converter or exhaust manifold pipe with adjustable jackstands. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4183 6. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the left exhaust manifold pipe nuts. 7. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the right exhaust manifold pipe nuts. 8. If equipped with a 6.0L or 8.1L engine, remove the right exhaust manifold pipe nuts. 9. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Remove the left exhaust manifold pipe nuts. 2. Remove the exhaust hanger mounting bracket bolts. 10. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 11. Remove the exhaust manifold pipe seal(s). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4184 1. Install the exhaust manifold pipe seal(s). 2. Raise the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 3. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Install the exhaust hanger mounting bracket bolts. 2. Install the left exhaust manifold pipe nuts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). ^ Tighten the nuts to 50 Nm (39 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. If equipped with a 6.0L or 8.1L engine, install the right exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 5. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the right exhaust manifold pipe nuts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4185 6. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the left exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 7. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Connect the oxygen sensor electrical connector (1). 2. Connect the CPA retainer. 8. Remove the adjustable jackstands from catalytic converter or exhaust manifold pipe. 9. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Connect the oxygen sensor electrical connector (1). 2. Connect the CPA retainer. 3. Clip the oxygen sensor electrical connector to the hose clip. 10. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4186 1. Connect the forward oxygen sensor electrical connector. 2. Connect the CPA retainer. 3. Install the clip around the engine harness and the oxygen sensor pigtail. 11. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications > Page 4193 Body Control Module (BCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4210 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4211 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4212 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4213 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4214 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4215 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4216 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4217 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4218 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4219 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4220 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4223 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4226 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4227 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4228 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4229 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4246 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4247 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4248 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4252 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4254 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4258 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 Body Control Module (BCM) - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 Body Control Module (BCM) - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 Body Control Module: Electrical Diagrams Body Control System Diagrams Body Control System Diagram 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 Body Control System Diagram 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 Body Control System Diagram 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4284 Body Control System Diagram 4 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4285 Body Control System Diagram 4 (2 Of 2) Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Computer/Integrating Systems Computer/Integrating Systems Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4286 Power, Ground, DLC and Splice Pack SP 205 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4287 Splice Pack SP 207 Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Door Control Module Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4288 Door Control Module Diagram 1 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4289 Door Control Module Diagram 1 (2 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4290 Door Control Module Diagram 2 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4291 Door Control Module Diagram 2 (2 Of 2) Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagram can be found via their numbers at Vehicle Locations. See: Locations Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION BCM FUNCTIONS The body control module (BCM) performs multiple body control functions. The BCM can control devices directly connected to its outputs based on input information. The BCM evaluates this information and controls certain body control systems by commanding outputs on or off. The BCM control inputs can be: Sensors and switches that are directly connected to the BCM - Class 2 serial data received from other control modules connected to the class 2 serial data link. The BCM is also capable of controlling other vehicle systems that are not directly wired to the BCM. The BCM does this by sending specific messages on the class 2 serial data link. The control module capable of performing the required function will respond to the BCM message. The BCM controls these functions: Audible warnings, refer to Audible Warnings Description and Operation in Instrument Panel, Gages and Console - Automatic door locks, refer to Power Door Locks Description and Operation in Doors - Automatic headlamp control, refer to Exterior Lighting Systems Description and Operation in Lighting Systems - Interior lighting, refer to Interior Lighting Systems Description and Operation in Lighting Systems - Keyless entry (AUO option), refer to Keyless Entry System Description and Operation in Keyless Entry. - Passlock theft deterrent, refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Retained Accessory Power (RAP), refer to Retained Accessory Power (RAP) Description and Operation POWER MODE The BCM is the power mode master (PMM). Refer to Power Mode Description and Operation for more information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 4294 Body Control Module: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The serial data communication among the control modules is performed through multiple serial data communication links. The class 2 serial data line is always present. The high speed GMLAN or controller area network (CAN) may be present for different vehicle options. The data link connector (DLC) allows a scan tool to communicate with the modules on class 2 or high speed GMLAN serial data lines. In order for the scan tool to communicate with the modules on high speed GMLAN link, a CANdi module is needed. The CANdi module behaves as an interface between the scan tool and the high speed GMLAN data link. The CAN is used for functional communication only, among the modules connected to it. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 - Class 2 signal at terminal 2 - High speed GMLAN serial data bus (+) at terminal 6 - High speed GMLAN serial data bus (-) at terminal 14 CLASS 2 SERIAL DATA LINE Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The class 2 serial data line on this vehicle is a star configuration. The powertrain control module (PCM) has an additional class 2 serial data circuit to body control module (BCM). If one of the class 2 serial data circuits to the PCM opens, communication will not be interrupted. The following modules communicate on the class 2 serial data line: The audio amplifier (AMP), w/UQ7 and Y91 - The body control module (BCM) - The communication interface module (OnStar(R)), w/UE1 - The digital radio receiver (DRR), w/U2K - The driver door module (DDM) - The electronic brake control module (EBCM) - The generator battery control module (GBCM) - The HVAC control module - The hybrid control module (HCM), w/HP2 - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The memory seat module (MSM), w/AN3 - The passenger door module (PDM) - The powertrain/engine control module (PCM/ECM) - The radio - The rear seat audio (RSA) controller, w/UK6 - The rear seat entertainment (RSE) assembly w/U42 - The rear wheel steering control module (RWSCM), w/NYS - The remote playback device - CD player (CDX), w/U1S - The transfer case shift control module (TCSCM), w/NP1/NP8 - The transmission control module (TCM), w/M74 The class 2 serial data line allows a scan tool to communicate with these modules for testing purposes, checking for DTCs, and to activate/enable/disable functions. These class 2 serial data circuits are bussed together via 2 splice packs: SP205-Located behind the instrument panel (I/P) near the headlamp switch connector. - SP207-Located in the I/P harness. Refer to Computer/Integrating Systems Component Views. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 4295 HIGH SPEED GMLAN SERIAL DATA LINE (PHT) The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit through the CANdi module. The serial data is transmitted on two twisted wires that allow speed up to 500 Kbps. The twisted pair is terminated with two 120-ohm resistors, one is internal to the engine control module (ECM) and the other is internal to the energy storage control module (ESCM). The resistors are used to reduce noise on the high speed GMLAN bus during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level which is approximately 2.5 volts is considered a recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes adds 1 volt to high speed GMLAN serial data bus (+) and subtracts 1 volt from high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles's functionality has been requested. A virtual network is supported by virtual devices which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Failsofting is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a "heartbeat" of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped as a code against the physical device. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The powertrain control module (PCM) and hybrid control module (HCM) are functionally communicating on both class 2 and high speed GMLAN data links. However the diagnostic communication of the above modules with the scan tool is performed on class 2 data link only. All DTCs set by the high speed GMLAN modules, including HCM, are reported by the PCM on class 2. Data displaying, output controls and programming of the control modules connected to high speed GMLAN only, is performed through high speed GMLAN link. The GMLAN serial data communications circuit is in a linear topology. The following modules are connected to the link, in order from DLC to the end of the linear configuration: The energy storage control module (ESCM) - The starter/generator control module (SGCM) - The electro-hydraulic power steering (EHPS) - The hybrid control module (HCM) - The powertrain control module (PCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 4296 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION SERIAL DATA POWER MODE On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle the PMM is the body control module (BCM). The BCM uses 3 signals from the ignition switch. These are the Ignition 0, Ignition 1, and Accessory. To determine the correct power mode the BCM uses: The state of these signals - The sequence of switch closures received by the BCM - The status of the engine run flag The chart indicates the power modes detected and transmitted by the BCM: FAIL-SAFE OPERATION Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the BCM fail to send a power mode message. The fail-safe plan covers modules with discrete ignition signal inputs as well as those modules using exclusively serial data control of power mode. SERIAL DATA MESSAGES The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid BCM message until they receive the engine status from the PCM. If the BCM fails, the modules monitor the serial data circuit for the engine run flag serial data. If the engine run flag serial data is true, indicating that the engine is running, the modules fail-safe to Run. In this state the modules and their subsystems can support all operator requirements. If the engine run flag serial data is false, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. DISCRETE IGNITION SIGNALS Those modules that have discrete ignition signal inputs also remain in the state dictated by the last valid BCM message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, B+, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 voltage, the modules will fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 4297 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4300 Body Control Module: Symptom Related Diagnostic Procedures - Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description and Operation - Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Scan Tool Does Not Power Up See: Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with Class 2 Device See: Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With High Speed GMLAN Device - Power Mode Mismatch See: Power Mode Mismatch - Retained Accessory Power (RAP) On After Timeout See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) Inoperative Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4301 Steps 1-6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4302 Steps 1-6 Power Mode Mismatch POWER MODE MISMATCH CIRCUIT DESCRIPTION Normal vehicle class 2 communications and module operations will not begin until the system power mode has been identified. Discrete wires from the ignition switch contacts are monitored by the power mode master (PMM) module in order to determine the correct power mode. The PMM communicates the system power mode to all class 2 modules on the class 2 serial data line. Refer to Body Control System Description and Operation to identify which module is the PMM and the applicable power mode look up table. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4303 Steps 1-6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4304 Steps 7-14 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4305 Step 15 The numbers below refer to the step numbers on the diagnostic table. 7. This step tests for battery voltage on the signal circuits that are not required. 8. This step tests for no battery voltage on the required signal circuits. 9. If any ignition switch parameters that should be inactive in the present ignition switch position are active, 2 ignition switch signal circuits may be shorted together. 10. This step eliminates open circuits as the cause of the malfunction. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4306 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Battery Voltage: The scan tool displays 0.0-16.0 volts. The battery voltage input represents the system voltage measured at the BCM ignition feed input. (Driver/Passenger) Door Ajar Switch (w/o DDM or w/o PDM)): Input from the respecting door indicating door status. Ignition Accessory: Input from ignition switch Accessory circuit. Used to determine power mode. Hot in ACC and ON. Ignition 0: Input to the control module from the ignition switch indicating the Ignition 0 position. Switch closed (HOT) in ignition switch positions UNLOCK, ACC, ON, and START Ignition 1: Input to the control module from the ignition switch indicating the Ignition 1 position. Switch closed (HOT) in ignition switch positions ON and START. Key in Ignition: Input from ignition switch indicating that the ignition key is inserted into the ignition switch. HOT with key in ignition switch. Julian Date of Build: The day of the year when module was built. Left Rear/Rear Cargo Door Ajar Switch: Input from the left rear/rear cargo door showing the state of it. Right Rear Door Ajar Sw.: Input from the right rear door showing the state of it. SWC Switch Power: Indicates the state of the supply voltage to the steering wheel controls supply voltage. SWC Switch Voltage: Indicates the steering wheel controls supply voltage. Year Module Built: The year when module was built. 8 Digit GM Part Number: The module's part number. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4307 Scan Tool Data List Scan Tool Output Controls Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function "Request BCM Info. for SPS", then connect the scan tool to the SPS terminal and follow the instructions on the screen. Refer to Service Programming System (SPS) in Programming and Setup. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4310 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cables. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the body control module (BCM) from the sliding bracket. INSTALLATION PROCEDURE 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4311 4. Install the knee bolster. 5. Connect the negative battery cables. 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations THROTTLE ACTUATOR CONTROL MODULE Throttle Actuator Control (TAC) Module The Throttle Actuator Control Module (TAC) is located in the left rear of the engine compartment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 4315 Electronic Throttle Control Module: Diagrams C1 Throttle Actuator Control (TAC) Module C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 4316 C2 Throttle Actuator Control (TAC) Module C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 4317 Electronic Throttle Control Module: Service and Repair Electronic Throttle Actuator Control Module Replacement Removal Procedure 1. Disconnect the instrument panel (I/P) harness electrical connector (2). 2. Release the red connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1). 4. Remove the throttle actuator control (TAC) module nuts. 5. Remove the TAC module. Installation Procedure 1. Install the TAC module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 4318 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the TAC module nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Connect the engine wiring harness electrical connector (1). 4. Install the red CPA retainer. 5. Connect the I/P harness electrical connector (2). 6. Refer to Control Module References for programming and setup information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4327 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4328 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4329 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4330 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4331 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4332 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4333 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 4339 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement Engine Control Module: Customer Interest Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement > Page 4344 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 4350 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 4355 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4364 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4365 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4366 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4367 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4368 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4369 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4370 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls Battery Lamp ON After PCM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls Battery Lamp ON After PCM Replacement > Page 4375 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 4381 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 4386 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement > Page 4395 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 4401 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4410 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4411 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4412 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4413 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4414 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4415 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 4416 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4417 Powertrain Control Module (PCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 Engine Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4431 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4432 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4433 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4434 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4436 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4437 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4439 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4440 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4441 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4442 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4467 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4468 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4469 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4470 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4472 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4473 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4486 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4487 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4488 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4489 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4490 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4494 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 Powertrain Control Module (PCM) C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Powertrain Control Module (PCM) C2 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 4506 - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. MIL Request: Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 4507 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4508 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. Removal Procedure IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. If equipped with regular production option (RPO) NYS, remove the harness ground clip from the PCM cover. 4. If equipped with RPO HP2, remove the hybrid control module (HCM). 5. If vehicle is NOT equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4509 6. If vehicle is equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. 7. Loosen the PCM electrical connector bolts (2). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 8. Disconnect the PCM electrical connectors. 9. Release the spring latch from the PCM. 10. Release the PCM mounting tabs from the PCM. 11. Remove the PCM. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4510 1. Install the PCM.Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Tighten the bolts to 8 N.m (71 lb in). 5. If vehicle is equipped with RPO HP2, install the PCM cover. 6. If vehicle is NOT equipped with RPO HP2, install the PCM cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4511 7. If equipped with RPO HP2, install the HCM. 8. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 9. Connect the negative battery cable. 10. If a NEW PCM was installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 4517 Fuse Block - Underhood Label The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 4518 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Underhood Fuse Block The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4530 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4531 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4532 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4533 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4543 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4544 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4545 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4552 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4553 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4554 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4555 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4564 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4565 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4566 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4567 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4568 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4569 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4570 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4571 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4572 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4578 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4579 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 Fuel Pump (FP) Relay - Secondary (w/Dual Tanks) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The PCM 1 fuse - The ETC/ECM fuse - The INJ 1 fuse - The INJ 2 fuse - The SBA fuse, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4602 Steps 1-7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4603 Steps 8-17 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4604 Steps 18-26 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4605 Steps 27-31 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4611 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4612 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4613 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4614 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4697 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4698 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations CAMSHAFT POSITION SENSOR The Camshaft Position Sensor (CMP) is located on the top rear center of engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4710 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4711 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4712 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4713 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4714 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4715 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4716 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4717 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4718 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4722 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4723 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4724 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4725 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4726 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4776 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4777 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4784 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4785 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations SEO Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4792 Left Side Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4793 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4794 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4795 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4845 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4846 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4847 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4849 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4851 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4852 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4853 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4854 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4857 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4858 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4859 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4860 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4861 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4862 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4863 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4864 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4865 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4866 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 Crankshaft Position (CKP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4877 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4880 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4881 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel System (Cab Chassis) Fuel Level Sensor: Description and Operation Fuel System (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (I/P) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the powertrain control module (PCM). The PCM calculates the total fuel level in both tanks. The instrument panel (I/P) fuel gage displays the total fuel level in both fuel tanks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel System (Cab Chassis) > Page 4887 Fuel Level Sensor: Description and Operation Fuel System (Pickup and Utility) FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 4890 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 4891 1. Install the fuel level sensor. 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 4892 4. Install the fuel level sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 4893 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 44402 Fuel Tank Sending Unit Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect fuel lines from the sending unit, if required. 3. Using J 44402, remove the sending unit lock ring. 4. Remove the sending unit and seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 5. Clean the sending unit sealing surfaces. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 4894 assure that the fuel strainer does not block full travel of the float arm. 1. Install a NEW sending unit seal. 2. Align the tab, and install the sending unit. 3. Using J 44402, install the sending unit lock ring. 4. Connect fuel lines to the sending unit, if required. 5. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4898 Fuel Tank Pressure (FTP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4899 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4900 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4904 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4905 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4906 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4990 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4991 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4992 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Top Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4996 Manifold Absolute Pressure (MAP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4997 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4998 1. Install the MAP sensor (1). 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required ^ J41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 5005 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J41712 or equivalent, install the oil pressure sensor. Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 5014 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 5020 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 5021 HO2S Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5024 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5042 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5050 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5098 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5099 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5100 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5106 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5107 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5108 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5109 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5110 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5111 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5112 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 5117 Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 5120 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 5123 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 5124 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 5125 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 5126 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 5127 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5132 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5133 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5134 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5135 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5186 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5187 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5215 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5218 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5219 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations Fuel Composition Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 5223 Fuel Composition Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 5224 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The fuel composition sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the powertrain control module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing -40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 41/2 percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 5225 Steps 1-5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 5226 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the fuel composition sensor electrical connector. 4. Remove the fuel line retainers (1). 5. Disconnect the fuel composition sensor fuel lines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 5227 6. Remove the fuel composition sensor bracket nuts. 7. Remove the fuel composition sensor. 8. If required, remove the fuel composition sensor bolts and remove the sensor from the bracket. INSTALLATION PROCEDURE 1. If required, install the fuel composition sensor to the bracket and install the bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten bolts to 10 N.m (89 lb in). 2. Install the fuel composition sensor. 3. Install the fuel composition sensor bracket nuts. Tighten nuts to 17 N.m (13 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 5228 4. Connect the fuel composition sensor fuel lines. 5. Install the fuel line retainers (1). 6. Connect the fuel composition sensor electrical connector. 7. Lower the vehicle. 8. Use the following procedure in order to inspect for leaks: - Turn the ignition ON, with the engine OFF, for 2 seconds. - Turn the ignition OFF for 10 seconds. - Turn the ignition ON, with the engine OFF. - Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations CAMSHAFT POSITION SENSOR The Camshaft Position Sensor (CMP) is located on the top rear center of engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5240 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5241 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5242 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5243 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5244 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5245 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5246 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5247 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5248 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5249 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5250 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5251 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5252 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5253 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5254 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5255 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5256 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5257 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5258 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5259 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5260 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5261 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5268 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5269 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5270 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5271 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5272 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5273 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5274 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5312 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5313 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5336 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5337 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5367 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5368 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5369 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5370 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5371 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5372 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5373 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5374 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5375 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5376 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5377 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5378 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 Crankshaft Position (CKP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5395 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5398 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5399 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5405 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5406 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5418 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5419 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5420 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5421 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5422 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5423 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5424 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5425 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5447 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5452 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5483 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5484 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5485 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................385-425 kPa (55-62 psi) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5492 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5493 Steps 1-4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5494 Steps 5-13 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5507 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5513 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5514 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5515 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 5521 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. Refer to Fuel Pressure Gage Installation and Removal. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. .........................................................1,000 ohms per ft Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 5525 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 5526 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: IMPORTANT: The Melco(R) spark plug wires MUST be used only with the Melco(R) coils and bracket, like wise the Delphi(R) spark plug wires MUST be used only with Delphi(R) coils and bracket. The components are NOT interchangeable. 4. The Melco(R) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(R) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. 6. The Melco(R) (1) ignition coil is a square design. 7. The Delphi(R) (2) ignition coil is a round design. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 5527 8. The Melco(R) ignition coil bracket (1) is a square design. 9. The Delphi(R) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ............................................ 1.02 mm (0.04 inches) Spark Plug Torque ............................................. ................................................................................................................................... 15 Nm (11 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 5531 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................... AC 25171803 (NGK 12567759) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 5532 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 5533 - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 5534 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 5535 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Spark plug gap: 1.016 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. - Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 5. Install the spark plug wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 5539 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Check the compression again and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1,035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5544 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5545 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5546 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5547 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5620 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5621 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5622 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5630 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5631 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5635 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5636 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5637 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Specifications > Page 5641 Body Control Module (BCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5676 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5677 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5678 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5679 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5680 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5681 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5682 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5683 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 Body Control Module (BCM) - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 Body Control Module (BCM) - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Body Control Module: Electrical Diagrams Body Control System Diagrams Body Control System Diagram 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 Body Control System Diagram 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 Body Control System Diagram 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Body Control System Diagram 4 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 Body Control System Diagram 4 (2 Of 2) Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Computer/Integrating Systems Computer/Integrating Systems Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 Power, Ground, DLC and Splice Pack SP 205 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Splice Pack SP 207 Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Door Control Module Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 Door Control Module Diagram 1 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 Door Control Module Diagram 1 (2 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 Door Control Module Diagram 2 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 Door Control Module Diagram 2 (2 Of 2) Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagram can be found via their numbers at Vehicle Locations. See: Locations Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION BCM FUNCTIONS The body control module (BCM) performs multiple body control functions. The BCM can control devices directly connected to its outputs based on input information. The BCM evaluates this information and controls certain body control systems by commanding outputs on or off. The BCM control inputs can be: Sensors and switches that are directly connected to the BCM - Class 2 serial data received from other control modules connected to the class 2 serial data link. The BCM is also capable of controlling other vehicle systems that are not directly wired to the BCM. The BCM does this by sending specific messages on the class 2 serial data link. The control module capable of performing the required function will respond to the BCM message. The BCM controls these functions: Audible warnings, refer to Audible Warnings Description and Operation in Instrument Panel, Gages and Console - Automatic door locks, refer to Power Door Locks Description and Operation in Doors - Automatic headlamp control, refer to Exterior Lighting Systems Description and Operation in Lighting Systems - Interior lighting, refer to Interior Lighting Systems Description and Operation in Lighting Systems - Keyless entry (AUO option), refer to Keyless Entry System Description and Operation in Keyless Entry. - Passlock theft deterrent, refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Retained Accessory Power (RAP), refer to Retained Accessory Power (RAP) Description and Operation POWER MODE The BCM is the power mode master (PMM). Refer to Power Mode Description and Operation for more information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5742 Body Control Module: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The serial data communication among the control modules is performed through multiple serial data communication links. The class 2 serial data line is always present. The high speed GMLAN or controller area network (CAN) may be present for different vehicle options. The data link connector (DLC) allows a scan tool to communicate with the modules on class 2 or high speed GMLAN serial data lines. In order for the scan tool to communicate with the modules on high speed GMLAN link, a CANdi module is needed. The CANdi module behaves as an interface between the scan tool and the high speed GMLAN data link. The CAN is used for functional communication only, among the modules connected to it. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 - Class 2 signal at terminal 2 - High speed GMLAN serial data bus (+) at terminal 6 - High speed GMLAN serial data bus (-) at terminal 14 CLASS 2 SERIAL DATA LINE Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The class 2 serial data line on this vehicle is a star configuration. The powertrain control module (PCM) has an additional class 2 serial data circuit to body control module (BCM). If one of the class 2 serial data circuits to the PCM opens, communication will not be interrupted. The following modules communicate on the class 2 serial data line: The audio amplifier (AMP), w/UQ7 and Y91 - The body control module (BCM) - The communication interface module (OnStar(R)), w/UE1 - The digital radio receiver (DRR), w/U2K - The driver door module (DDM) - The electronic brake control module (EBCM) - The generator battery control module (GBCM) - The HVAC control module - The hybrid control module (HCM), w/HP2 - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The memory seat module (MSM), w/AN3 - The passenger door module (PDM) - The powertrain/engine control module (PCM/ECM) - The radio - The rear seat audio (RSA) controller, w/UK6 - The rear seat entertainment (RSE) assembly w/U42 - The rear wheel steering control module (RWSCM), w/NYS - The remote playback device - CD player (CDX), w/U1S - The transfer case shift control module (TCSCM), w/NP1/NP8 - The transmission control module (TCM), w/M74 The class 2 serial data line allows a scan tool to communicate with these modules for testing purposes, checking for DTCs, and to activate/enable/disable functions. These class 2 serial data circuits are bussed together via 2 splice packs: SP205-Located behind the instrument panel (I/P) near the headlamp switch connector. - SP207-Located in the I/P harness. Refer to Computer/Integrating Systems Component Views. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5743 HIGH SPEED GMLAN SERIAL DATA LINE (PHT) The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit through the CANdi module. The serial data is transmitted on two twisted wires that allow speed up to 500 Kbps. The twisted pair is terminated with two 120-ohm resistors, one is internal to the engine control module (ECM) and the other is internal to the energy storage control module (ESCM). The resistors are used to reduce noise on the high speed GMLAN bus during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level which is approximately 2.5 volts is considered a recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes adds 1 volt to high speed GMLAN serial data bus (+) and subtracts 1 volt from high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles's functionality has been requested. A virtual network is supported by virtual devices which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Failsofting is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a "heartbeat" of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped as a code against the physical device. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The powertrain control module (PCM) and hybrid control module (HCM) are functionally communicating on both class 2 and high speed GMLAN data links. However the diagnostic communication of the above modules with the scan tool is performed on class 2 data link only. All DTCs set by the high speed GMLAN modules, including HCM, are reported by the PCM on class 2. Data displaying, output controls and programming of the control modules connected to high speed GMLAN only, is performed through high speed GMLAN link. The GMLAN serial data communications circuit is in a linear topology. The following modules are connected to the link, in order from DLC to the end of the linear configuration: The energy storage control module (ESCM) - The starter/generator control module (SGCM) - The electro-hydraulic power steering (EHPS) - The hybrid control module (HCM) - The powertrain control module (PCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5744 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION SERIAL DATA POWER MODE On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle the PMM is the body control module (BCM). The BCM uses 3 signals from the ignition switch. These are the Ignition 0, Ignition 1, and Accessory. To determine the correct power mode the BCM uses: The state of these signals - The sequence of switch closures received by the BCM - The status of the engine run flag The chart indicates the power modes detected and transmitted by the BCM: FAIL-SAFE OPERATION Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the BCM fail to send a power mode message. The fail-safe plan covers modules with discrete ignition signal inputs as well as those modules using exclusively serial data control of power mode. SERIAL DATA MESSAGES The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid BCM message until they receive the engine status from the PCM. If the BCM fails, the modules monitor the serial data circuit for the engine run flag serial data. If the engine run flag serial data is true, indicating that the engine is running, the modules fail-safe to Run. In this state the modules and their subsystems can support all operator requirements. If the engine run flag serial data is false, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. DISCRETE IGNITION SIGNALS Those modules that have discrete ignition signal inputs also remain in the state dictated by the last valid BCM message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, B+, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 voltage, the modules will fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5745 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5748 Body Control Module: Symptom Related Diagnostic Procedures - Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description and Operation - Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Scan Tool Does Not Power Up See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with Class 2 Device See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With High Speed GMLAN Device - Power Mode Mismatch See: Power Mode Mismatch - Retained Accessory Power (RAP) On After Timeout See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) Inoperative Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5749 Steps 1-6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5750 Steps 1-6 Power Mode Mismatch POWER MODE MISMATCH CIRCUIT DESCRIPTION Normal vehicle class 2 communications and module operations will not begin until the system power mode has been identified. Discrete wires from the ignition switch contacts are monitored by the power mode master (PMM) module in order to determine the correct power mode. The PMM communicates the system power mode to all class 2 modules on the class 2 serial data line. Refer to Body Control System Description and Operation to identify which module is the PMM and the applicable power mode look up table. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5751 Steps 1-6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5752 Steps 7-14 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5753 Step 15 The numbers below refer to the step numbers on the diagnostic table. 7. This step tests for battery voltage on the signal circuits that are not required. 8. This step tests for no battery voltage on the required signal circuits. 9. If any ignition switch parameters that should be inactive in the present ignition switch position are active, 2 ignition switch signal circuits may be shorted together. 10. This step eliminates open circuits as the cause of the malfunction. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5754 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Battery Voltage: The scan tool displays 0.0-16.0 volts. The battery voltage input represents the system voltage measured at the BCM ignition feed input. (Driver/Passenger) Door Ajar Switch (w/o DDM or w/o PDM)): Input from the respecting door indicating door status. Ignition Accessory: Input from ignition switch Accessory circuit. Used to determine power mode. Hot in ACC and ON. Ignition 0: Input to the control module from the ignition switch indicating the Ignition 0 position. Switch closed (HOT) in ignition switch positions UNLOCK, ACC, ON, and START Ignition 1: Input to the control module from the ignition switch indicating the Ignition 1 position. Switch closed (HOT) in ignition switch positions ON and START. Key in Ignition: Input from ignition switch indicating that the ignition key is inserted into the ignition switch. HOT with key in ignition switch. Julian Date of Build: The day of the year when module was built. Left Rear/Rear Cargo Door Ajar Switch: Input from the left rear/rear cargo door showing the state of it. Right Rear Door Ajar Sw.: Input from the right rear door showing the state of it. SWC Switch Power: Indicates the state of the supply voltage to the steering wheel controls supply voltage. SWC Switch Voltage: Indicates the steering wheel controls supply voltage. Year Module Built: The year when module was built. 8 Digit GM Part Number: The module's part number. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5755 Scan Tool Data List Scan Tool Output Controls Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function "Request BCM Info. for SPS", then connect the scan tool to the SPS terminal and follow the instructions on the screen. Refer to Service Programming System (SPS) in Programming and Setup. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 5758 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cables. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the body control module (BCM) from the sliding bracket. INSTALLATION PROCEDURE 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 5759 4. Install the knee bolster. 5. Connect the negative battery cables. 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Brake Pressure Switch > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations CAMSHAFT POSITION SENSOR The Camshaft Position Sensor (CMP) is located on the top rear center of engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5789 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5790 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5791 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5792 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5793 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5794 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5795 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5846 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5847 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations SEO Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 5854 Left Side Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 5855 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 5856 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 5857 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5917 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5918 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5919 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5920 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5921 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5922 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5923 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5924 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5925 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5926 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5927 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5928 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5929 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5930 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5931 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5932 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5934 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5935 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5936 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5937 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 Crankshaft Position (CKP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 5939 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5942 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5943 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Lower Left Of The I/P Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 5947 Data Link Connector: Service and Repair DATA LINK CONNECTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the bolt from the data link connector (DLC). 2. Remove the DLC from the instrument panel (I/P). INSTALLATION PROCEDURE 1. Install the DLC to the I/P. 2. Install the DLC bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Description and Operation Electronic Throttle Actuator: Description and Operation THROTTLE ACTUATOR CONTROL (TAC) SYSTEM DESCRIPTION The throttle actuator control (TAC) system delivers improved throttle response and greater reliability and eliminates the need for mechanical cable. The TAC system performs the following functions: - Accelerator pedal position (APP) sensing - Throttle positioning to meet driver and engine demands - Throttle position sensing - Internal diagnostics - Cruise control functions - Manage TAC electrical power consumption The TAC system components include the following: - The APP sensors - The throttle body assembly - The TAC module - The powertrain control module (PCM) Accelerator Pedal Position (APP) Sensor The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Throttle Body Assembly The throttle body assembly consists of the throttle body, the throttle position (TP) sensors, and the throttle actuator motor. The throttle body functions similar to a similar to a conventional throttle body with the following exceptions: An electric motor opens and closes the throttle valve. - The throttle blade is spring loaded in both directions and the default position is slightly open. - There are 2 individual TP sensors within the throttle body assembly. The TP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: A 5-volt reference circuit - A low reference circuit - A signal circuit The TP sensors are used to determine the throttle plate angle. The control module provides each TP sensor a 5-volt reference circuit and a low reference circuit. The TP sensors then provide the control module with signal voltage proportional to throttle plate movement. Both TP sensor signal voltages are low at closed throttle and increase as the throttle opens. Throttle Actuator Control Module The throttle actuator control (TAC) module is the control center for the throttle actuator control system. The TAC system is self-diagnosing and provides diagnostic information to the powertrain control module (PCM) through a dedicated serial data line. The TAC achieves throttle positioning by providing a pulse width modulated voltage to the TAC, as directed by the PCM. Powertrain Control Module The powertrain control module (PCM) determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the throttle actuator control (TAC) module through a dedicated serial data line. Modes of Operation Normal Mode During the operation of the throttle actuator control (TAC) system, several modes or functions are considered normal. The following modes may be entered during normal operation: Minimum pedal value-At key-up the powertrain control module (PCM) updates the learned minimum pedal value. - Minimum throttle position (TP) values-At key-up the PCM updates the learned minimum TP value. In order to learn the minimum TP value, the throttle blade is moved to the closed position. - Ice break mode-If the throttle is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the control module commands the maximum pulse width several times to the throttle actuator motor in the closing direction. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Description and Operation > Page 5951 - Battery saver mode-After a predetermined time without engine RPM, the control module commands the battery saver mode. During the battery saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position. Reduced Engine Power Mode When the PCM detects a condition with the TAC system, the PCM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions: Acceleration limiting-The control module will continue to use the accelerator pedal for throttle control; however, the vehicle acceleration is limited. - Limited throttle mode-The control module will continue to use the accelerator pedal for throttle control; however, the maximum throttle opening is limited. - Throttle default mode-The control module will turn off the throttle actuator motor and the throttle will return to the spring loaded default position. - Forced idle mode-The control module will perform the following actions: Limit engine speed to idle by positioning throttle position, or by controlling fuel and spark if throttle is turned off. - Ignore accelerator pedal input. - Engine shutdown mode-The control module will disable fuel and de-energize the throttle actuator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations THROTTLE ACTUATOR CONTROL MODULE Throttle Actuator Control (TAC) Module The Throttle Actuator Control Module (TAC) is located in the left rear of the engine compartment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5955 Electronic Throttle Control Module: Diagrams C1 Throttle Actuator Control (TAC) Module C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5956 C2 Throttle Actuator Control (TAC) Module C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5957 Electronic Throttle Control Module: Service and Repair Electronic Throttle Actuator Control Module Replacement Removal Procedure 1. Disconnect the instrument panel (I/P) harness electrical connector (2). 2. Release the red connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1). 4. Remove the throttle actuator control (TAC) module nuts. 5. Remove the TAC module. Installation Procedure 1. Install the TAC module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5958 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the TAC module nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Connect the engine wiring harness electrical connector (1). 4. Install the red CPA retainer. 5. Connect the I/P harness electrical connector (2). 6. Refer to Control Module References for programming and setup information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 5967 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 5968 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 5969 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 5970 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 5971 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 5972 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 5973 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls MIL ON/Misfire/Misfire DTC's Set > Page 5979 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-010A > Apr > 05 > Engine Controls Battery Lamp ON After PCM Replacement Engine Control Module: Customer Interest Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-010A > Apr > 05 > Engine Controls Battery Lamp ON After PCM Replacement > Page 5984 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 5990 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 5995 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls - Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6004 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6005 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6006 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6007 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6008 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6009 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6010 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement > Page 6015 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 6021 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 6026 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls - Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement > Page 6035 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 6041 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6050 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6051 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6052 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6053 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6054 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6055 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6056 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 6057 Powertrain Control Module (PCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 Engine Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Powertrain Control Module (PCM) C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Powertrain Control Module (PCM) C2 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 6146 - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. MIL Request: Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 6147 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6148 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. Removal Procedure IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. If equipped with regular production option (RPO) NYS, remove the harness ground clip from the PCM cover. 4. If equipped with RPO HP2, remove the hybrid control module (HCM). 5. If vehicle is NOT equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6149 6. If vehicle is equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. 7. Loosen the PCM electrical connector bolts (2). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 8. Disconnect the PCM electrical connectors. 9. Release the spring latch from the PCM. 10. Release the PCM mounting tabs from the PCM. 11. Remove the PCM. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6150 1. Install the PCM.Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Tighten the bolts to 8 N.m (71 lb in). 5. If vehicle is equipped with RPO HP2, install the PCM cover. 6. If vehicle is NOT equipped with RPO HP2, install the PCM cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6151 7. If equipped with RPO HP2, install the HCM. 8. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 9. Connect the negative battery cable. 10. If a NEW PCM was installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel System (Cab Chassis) Fuel Level Sensor: Description and Operation Fuel System (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (I/P) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the powertrain control module (PCM). The PCM calculates the total fuel level in both tanks. The instrument panel (I/P) fuel gage displays the total fuel level in both fuel tanks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel System (Cab Chassis) > Page 6157 Fuel Level Sensor: Description and Operation Fuel System (Pickup and Utility) FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 6160 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 6161 1. Install the fuel level sensor. 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 6162 4. Install the fuel level sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 6163 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 44402 Fuel Tank Sending Unit Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect fuel lines from the sending unit, if required. 3. Using J 44402, remove the sending unit lock ring. 4. Remove the sending unit and seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 5. Clean the sending unit sealing surfaces. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 6164 assure that the fuel strainer does not block full travel of the float arm. 1. Install a NEW sending unit seal. 2. Align the tab, and install the sending unit. 3. Using J 44402, install the sending unit lock ring. 4. Connect fuel lines to the sending unit, if required. 5. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 6168 Fuel Tank Pressure (FTP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 6169 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 6170 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 Information Bus: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6191 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6192 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6204 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6205 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6210 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6211 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6212 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6213 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6214 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6215 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6216 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6217 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6218 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6219 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6220 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6221 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6240 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6241 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6242 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6244 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6245 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6246 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6247 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6248 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6249 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6250 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 6251 Data Link Connector (DLC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Information Bus: Symptom Related Diagnostic Procedures Scan Tool Does Not Communicate With Class 2 Device SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the data link connector (DLC) allows communication with the modules for diagnostic purposes. DIAGNOSTIC AIDS The engine will not start when there is a total loss of class 2 serial data communication while the ignition is OFF. The following conditions will cause a total loss of class 2 serial data communication: A class 2 serial data circuit shorted to ground. - A class 2 serial data circuit shorted to voltage. - An internal condition within a module or connector on the class 2 serial data circuit, that causes a short to voltage or ground to the class 2 serial data circuit. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6254 Steps 1-11 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6255 Steps 12-19 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6256 Steps 20-27 The numbers below refer to the step numbers on the diagnostic table. 2. A partial malfunction in the class 2 serial data circuit uses a different procedure from a total malfunction of the class 2 serial data circuit. The following modules communicate on the class 2 serial data circuit: The audio amplifier (AMP), w/UQ7 and Y91 - The body control module (BCM) - The communication interface module (OnStar(R)), w/UE1 - The digital radio receiver (DRR), w/U2K - The driver door module (DDM) - The electronic brake control module (EBCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6257 - The generator battery control module (GBCM) - The HVAC control module - The hybrid control module (HCM), w/HP2 - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The memory seat module (MSM), w/AN3 - The passenger door module (PDM) - The powertrain/engine control module (PCM/ECM) - The radio - The rear seat audio (RSA) controller, w/UK6 - The rear seat entertainment (RSE) assembly w/U42 - The rear wheel steering control module (RWSCM), w/NYS - The remote playback device - CD player (CDX), w/U1S - The transfer case shift control module (TCSCM), w/NP1/NP8 - The transmission control module (TCM), w/M74 3. The following DTCs may be retrieved with a history status, but are not the cause of the present condition. - U1300 - U1301 - U1305 6. A state of health DTC with a history status may be present along with a U1000 or U1255 code having a current status. This indicates that the malfunction occurred when the ignition was ON. 7. Data link connector terminals 2 and 5 provide the connection to the class 2 serial data circuit and the signal ground circuit respectively. 10. A poor connection at DLC terminal of the splice pack SP205 would cause this condition but will not set a DTC. 11. An open or a short in the class 2 serial data circuit between the DLC and splice pack SP205 will prevent the scan tool from communicating with any module. This condition will not set a DTC. 13. This test isolates the BCM class 2 serial data circuits. 16. The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must remain connected to the DLC for any other module to communicate with the scan tool. This test isolates the splice pack SP207 serial data circuits. 21. This test isolates the rest of the splice pack SP205 serial data circuits. 25. If there are no current DTCs that begin with a "U", the communication malfunction has been repaired. 26. The communication malfunction may have prevented diagnosis of the customer complaint. Scan Tool Does Not Communicate With High Speed GMLAN Device SCAN TOOL DOES NOT COMMUNICATE WITH HIGH SPEED GMLAN DEVICE CIRCUIT DESCRIPTION Modules connected to the high speed GMLAN serial data circuits monitor for serial data communications on the high speed GMLAN network during normal vehicle operation. Operating information and commands are exchanged among the modules. The scan tool communicates with the following modules via the high speed GMLAN: Energy Storage Control Module (ESCM) - Starter/Generator Control Module (SGCM) - Electro-Hydraulic Power Steering (EHPS) Module DIAGNOSTIC AIDS IMPORTANT: The tool communication with the modules connected only to high speed GMLAN data link requires the use of the CANdi module. Due to configuration of this vehicle, they may be communication DTCs set against modules that are able to communicate with the scan tool. The following conditions may cause a total loss of high speed GMLAN data communication: A short between high speed GMLAN (+) and high speed GMLAN (-) circuits - Any of the high speed GMLAN serial data circuits shorted to ground or voltage - A module internal malfunction that causes a short to voltage or ground on the high speed GMLAN circuits TEST Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6258 Steps 1-9 Step 10 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6259 Scan Tool Does Not Power Up SCAN TOOL DOES NOT POWER UP CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Steps 1-4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly, the malfunction must be due to the scan tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6260 Information Bus: Scan Tool Testing and Procedures DATA LINK REFERENCES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6261 This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. This table is used to assist in correcting a communication malfunction between the control module and the scan tool. For the description and operation of these serial data communication circuits refer to Data Link Communications Description and Operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6267 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6268 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6270 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6271 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6272 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6273 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6274 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6275 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6276 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6277 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6278 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6279 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6280 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6281 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6282 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6283 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6284 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6285 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6286 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6287 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6288 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6289 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6290 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6291 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6292 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6293 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6294 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6295 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6296 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6297 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6298 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6299 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6300 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6301 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6302 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6303 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6304 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6305 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6306 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6307 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6308 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6309 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6312 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6334 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 6345 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 6346 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 6347 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On MALFUNCTION INDICATOR LAMP (MIL) ALWAYS ON CIRCUIT DESCRIPTION Voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The MIL is located on the instrument panel cluster (IPC). MIL Function The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the diagnostic. MIL Illumination - The MIL will illuminate with ignition switch ON and the engine not running. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Intermittent Conditions TEST DESCRIPTION Steps 1-7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 6352 The number below refers to the step number on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 6353 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative MALFUNCTION INDICATOR LAMP (MIL) INOPERATIVE CIRCUIT DESCRIPTION Voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL OPERATION The MIL is located on the instrument panel cluster (IPC). MIL Function The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the PCM. MIL Illumination The MIL will illuminate with ignition switch ON and the engine not running. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 6354 Steps 1-13 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 6355 Steps 14-16 The number below refers to the step number on the diagnostic table. 4. This step tests for a short to voltage on the MIL control circuit. With the fuse removed there should be no voltage on the MIL control circuit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Top Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 6359 Manifold Absolute Pressure (MAP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 6360 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 6361 1. Install the MAP sensor (1). 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required ^ J41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 6368 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J41712 or equivalent, install the oil pressure sensor. Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 6377 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 6383 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 6384 HO2S Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6387 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6388 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6389 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6390 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6391 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6392 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6393 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6469 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6470 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6471 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6472 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6473 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6474 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6475 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Specifications > Page 6480 Body Control Module (BCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6483 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6529 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6530 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6531 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6549 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6550 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6551 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6563 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6564 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6565 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6566 Body Control Module (BCM) - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6567 Body Control Module (BCM) - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6568 Body Control Module: Electrical Diagrams Body Control System Diagrams Body Control System Diagram 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 Body Control System Diagram 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 Body Control System Diagram 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 Body Control System Diagram 4 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 Body Control System Diagram 4 (2 Of 2) Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Computer/Integrating Systems Computer/Integrating Systems Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 Power, Ground, DLC and Splice Pack SP 205 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 Splice Pack SP 207 Location: The locations for the Connectors, Grounds, Splices, and grommets shown within these diagrams can be found via their numbers at vehicle locations. See: Locations Door Control Module Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 Door Control Module Diagram 1 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 Door Control Module Diagram 1 (2 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 Door Control Module Diagram 2 (1 Of 2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 Door Control Module Diagram 2 (2 Of 2) Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagram can be found via their numbers at Vehicle Locations. See: Locations Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION BCM FUNCTIONS The body control module (BCM) performs multiple body control functions. The BCM can control devices directly connected to its outputs based on input information. The BCM evaluates this information and controls certain body control systems by commanding outputs on or off. The BCM control inputs can be: Sensors and switches that are directly connected to the BCM - Class 2 serial data received from other control modules connected to the class 2 serial data link. The BCM is also capable of controlling other vehicle systems that are not directly wired to the BCM. The BCM does this by sending specific messages on the class 2 serial data link. The control module capable of performing the required function will respond to the BCM message. The BCM controls these functions: Audible warnings, refer to Audible Warnings Description and Operation in Instrument Panel, Gages and Console - Automatic door locks, refer to Power Door Locks Description and Operation in Doors - Automatic headlamp control, refer to Exterior Lighting Systems Description and Operation in Lighting Systems - Interior lighting, refer to Interior Lighting Systems Description and Operation in Lighting Systems - Keyless entry (AUO option), refer to Keyless Entry System Description and Operation in Keyless Entry. - Passlock theft deterrent, refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Retained Accessory Power (RAP), refer to Retained Accessory Power (RAP) Description and Operation POWER MODE The BCM is the power mode master (PMM). Refer to Power Mode Description and Operation for more information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6581 Body Control Module: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The serial data communication among the control modules is performed through multiple serial data communication links. The class 2 serial data line is always present. The high speed GMLAN or controller area network (CAN) may be present for different vehicle options. The data link connector (DLC) allows a scan tool to communicate with the modules on class 2 or high speed GMLAN serial data lines. In order for the scan tool to communicate with the modules on high speed GMLAN link, a CANdi module is needed. The CANdi module behaves as an interface between the scan tool and the high speed GMLAN data link. The CAN is used for functional communication only, among the modules connected to it. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 - Class 2 signal at terminal 2 - High speed GMLAN serial data bus (+) at terminal 6 - High speed GMLAN serial data bus (-) at terminal 14 CLASS 2 SERIAL DATA LINE Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The class 2 serial data line on this vehicle is a star configuration. The powertrain control module (PCM) has an additional class 2 serial data circuit to body control module (BCM). If one of the class 2 serial data circuits to the PCM opens, communication will not be interrupted. The following modules communicate on the class 2 serial data line: The audio amplifier (AMP), w/UQ7 and Y91 - The body control module (BCM) - The communication interface module (OnStar(R)), w/UE1 - The digital radio receiver (DRR), w/U2K - The driver door module (DDM) - The electronic brake control module (EBCM) - The generator battery control module (GBCM) - The HVAC control module - The hybrid control module (HCM), w/HP2 - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The memory seat module (MSM), w/AN3 - The passenger door module (PDM) - The powertrain/engine control module (PCM/ECM) - The radio - The rear seat audio (RSA) controller, w/UK6 - The rear seat entertainment (RSE) assembly w/U42 - The rear wheel steering control module (RWSCM), w/NYS - The remote playback device - CD player (CDX), w/U1S - The transfer case shift control module (TCSCM), w/NP1/NP8 - The transmission control module (TCM), w/M74 The class 2 serial data line allows a scan tool to communicate with these modules for testing purposes, checking for DTCs, and to activate/enable/disable functions. These class 2 serial data circuits are bussed together via 2 splice packs: SP205-Located behind the instrument panel (I/P) near the headlamp switch connector. - SP207-Located in the I/P harness. Refer to Computer/Integrating Systems Component Views. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6582 HIGH SPEED GMLAN SERIAL DATA LINE (PHT) The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit through the CANdi module. The serial data is transmitted on two twisted wires that allow speed up to 500 Kbps. The twisted pair is terminated with two 120-ohm resistors, one is internal to the engine control module (ECM) and the other is internal to the energy storage control module (ESCM). The resistors are used to reduce noise on the high speed GMLAN bus during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level which is approximately 2.5 volts is considered a recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes adds 1 volt to high speed GMLAN serial data bus (+) and subtracts 1 volt from high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles's functionality has been requested. A virtual network is supported by virtual devices which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Failsofting is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a "heartbeat" of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped as a code against the physical device. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The powertrain control module (PCM) and hybrid control module (HCM) are functionally communicating on both class 2 and high speed GMLAN data links. However the diagnostic communication of the above modules with the scan tool is performed on class 2 data link only. All DTCs set by the high speed GMLAN modules, including HCM, are reported by the PCM on class 2. Data displaying, output controls and programming of the control modules connected to high speed GMLAN only, is performed through high speed GMLAN link. The GMLAN serial data communications circuit is in a linear topology. The following modules are connected to the link, in order from DLC to the end of the linear configuration: The energy storage control module (ESCM) - The starter/generator control module (SGCM) - The electro-hydraulic power steering (EHPS) - The hybrid control module (HCM) - The powertrain control module (PCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6583 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION SERIAL DATA POWER MODE On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle the PMM is the body control module (BCM). The BCM uses 3 signals from the ignition switch. These are the Ignition 0, Ignition 1, and Accessory. To determine the correct power mode the BCM uses: The state of these signals - The sequence of switch closures received by the BCM - The status of the engine run flag The chart indicates the power modes detected and transmitted by the BCM: FAIL-SAFE OPERATION Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the BCM fail to send a power mode message. The fail-safe plan covers modules with discrete ignition signal inputs as well as those modules using exclusively serial data control of power mode. SERIAL DATA MESSAGES The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid BCM message until they receive the engine status from the PCM. If the BCM fails, the modules monitor the serial data circuit for the engine run flag serial data. If the engine run flag serial data is true, indicating that the engine is running, the modules fail-safe to Run. In this state the modules and their subsystems can support all operator requirements. If the engine run flag serial data is false, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. DISCRETE IGNITION SIGNALS Those modules that have discrete ignition signal inputs also remain in the state dictated by the last valid BCM message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, B+, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 voltage, the modules will fail-safe to OFF-AWAKE. In this state the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6584 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6587 Body Control Module: Symptom Related Diagnostic Procedures - Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description and Operation - Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Scan Tool Does Not Power Up See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with Class 2 Device See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With High Speed GMLAN Device - Power Mode Mismatch See: Power Mode Mismatch - Retained Accessory Power (RAP) On After Timeout See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) Inoperative Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6588 Steps 1-6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6589 Steps 1-6 Power Mode Mismatch POWER MODE MISMATCH CIRCUIT DESCRIPTION Normal vehicle class 2 communications and module operations will not begin until the system power mode has been identified. Discrete wires from the ignition switch contacts are monitored by the power mode master (PMM) module in order to determine the correct power mode. The PMM communicates the system power mode to all class 2 modules on the class 2 serial data line. Refer to Body Control System Description and Operation to identify which module is the PMM and the applicable power mode look up table. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6590 Steps 1-6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6591 Steps 7-14 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6592 Step 15 The numbers below refer to the step numbers on the diagnostic table. 7. This step tests for battery voltage on the signal circuits that are not required. 8. This step tests for no battery voltage on the required signal circuits. 9. If any ignition switch parameters that should be inactive in the present ignition switch position are active, 2 ignition switch signal circuits may be shorted together. 10. This step eliminates open circuits as the cause of the malfunction. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6593 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Battery Voltage: The scan tool displays 0.0-16.0 volts. The battery voltage input represents the system voltage measured at the BCM ignition feed input. (Driver/Passenger) Door Ajar Switch (w/o DDM or w/o PDM)): Input from the respecting door indicating door status. Ignition Accessory: Input from ignition switch Accessory circuit. Used to determine power mode. Hot in ACC and ON. Ignition 0: Input to the control module from the ignition switch indicating the Ignition 0 position. Switch closed (HOT) in ignition switch positions UNLOCK, ACC, ON, and START Ignition 1: Input to the control module from the ignition switch indicating the Ignition 1 position. Switch closed (HOT) in ignition switch positions ON and START. Key in Ignition: Input from ignition switch indicating that the ignition key is inserted into the ignition switch. HOT with key in ignition switch. Julian Date of Build: The day of the year when module was built. Left Rear/Rear Cargo Door Ajar Switch: Input from the left rear/rear cargo door showing the state of it. Right Rear Door Ajar Sw.: Input from the right rear door showing the state of it. SWC Switch Power: Indicates the state of the supply voltage to the steering wheel controls supply voltage. SWC Switch Voltage: Indicates the steering wheel controls supply voltage. Year Module Built: The year when module was built. 8 Digit GM Part Number: The module's part number. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6594 Scan Tool Data List Scan Tool Output Controls Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function "Request BCM Info. for SPS", then connect the scan tool to the SPS terminal and follow the instructions on the screen. Refer to Service Programming System (SPS) in Programming and Setup. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 6597 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cables. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the body control module (BCM) from the sliding bracket. INSTALLATION PROCEDURE 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 6598 4. Install the knee bolster. 5. Connect the negative battery cables. 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations THROTTLE ACTUATOR CONTROL MODULE Throttle Actuator Control (TAC) Module The Throttle Actuator Control Module (TAC) is located in the left rear of the engine compartment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 6602 Electronic Throttle Control Module: Diagrams C1 Throttle Actuator Control (TAC) Module C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 6603 C2 Throttle Actuator Control (TAC) Module C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 6604 Electronic Throttle Control Module: Service and Repair Electronic Throttle Actuator Control Module Replacement Removal Procedure 1. Disconnect the instrument panel (I/P) harness electrical connector (2). 2. Release the red connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1). 4. Remove the throttle actuator control (TAC) module nuts. 5. Remove the TAC module. Installation Procedure 1. Install the TAC module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 6605 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the TAC module nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Connect the engine wiring harness electrical connector (1). 4. Install the red CPA retainer. 5. Connect the I/P harness electrical connector (2). 6. Refer to Control Module References for programming and setup information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6614 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6615 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6616 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6617 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6618 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6619 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6620 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 6626 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement Engine Control Module: Customer Interest Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement > Page 6631 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 6637 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 6642 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls - Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6651 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6652 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6653 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6654 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6655 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6656 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6657 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement > Page 6662 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 6668 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 6673 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls - Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement > Page 6682 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 6688 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage Technical Service Bulletin # 05539A Date: 050427 Recall - PCM Integrated Circuit Chip Damage Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM # 05539A - (Apr 27, 2005) Models: 2005 CHEVROLET MALIBU, UPLANDER, EQUINOX, CLASSIC, SILVERADO 2005 GMC SIERRA 2005 PONTIAC SUNFIRE, GRAND AM, G6, GRAND PRIX, MONTANA SV6 2005 BUICK LACROSSE / ALLURLE, TERRAZA 2005 SATURN RELAY 2006 PONTIAC G6 THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints. Correction Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM). Vehicles Involved Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles and built within the VIN breakpoints shown. Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. Not all vehicles within the above breakpoints may be involved.] Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6697 Important: Saturn U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall claims will only be paid on involved vehicles. For US and Canada For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a Facility VIN List attachment to the Saturn Bulletin, located on DealerWorld. Dealers/Retailers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information (GM and Saturn Canada Only) Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Parts Information (Saturn US Only) A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO). Service Procedure Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6698 Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The SI document numbers are shown for your reference. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion. Recall Identification Label -- California, Massachusetts, Maine & Vermont Vehicles Only Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications. Courtesy Transportation - For US and Canada (GM Only) The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6699 Claim Information (GM and Saturn Canada Only) Submit a Product Recall Claim with the information shown. Claim Information (Saturn US Only) Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6700 Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. * * *THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT* * * When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials. Ask for GM Item Number 1825 when ordering. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6701 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6702 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05539A > Apr > 05 > Recall - PCM Integrated Circuit Chip Damage > Page 6703 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 6704 Powertrain Control Module (PCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6707 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Engine Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 Powertrain Control Module (PCM) C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Powertrain Control Module (PCM) C2 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 6793 - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. MIL Request: Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 6794 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6795 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. Removal Procedure IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. If equipped with regular production option (RPO) NYS, remove the harness ground clip from the PCM cover. 4. If equipped with RPO HP2, remove the hybrid control module (HCM). 5. If vehicle is NOT equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6796 6. If vehicle is equipped with RPO HP2, perform the following: 1. Release the PCM cover mounting tabs. 2. Release the PCM cover from the mounting bracket. 3. Remove the PCM cover. 7. Loosen the PCM electrical connector bolts (2). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 8. Disconnect the PCM electrical connectors. 9. Release the spring latch from the PCM. 10. Release the PCM mounting tabs from the PCM. 11. Remove the PCM. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6797 1. Install the PCM.Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Tighten the bolts to 8 N.m (71 lb in). 5. If vehicle is equipped with RPO HP2, install the PCM cover. 6. If vehicle is NOT equipped with RPO HP2, install the PCM cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6798 7. If equipped with RPO HP2, install the HCM. 8. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 9. Connect the negative battery cable. 10. If a NEW PCM was installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6803 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6804 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6805 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6806 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6828 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6829 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6830 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6831 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6832 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6833 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6834 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6835 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6836 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6837 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6838 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6839 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6840 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6841 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6842 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6843 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6844 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6845 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6846 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6847 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6848 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6849 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6850 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6851 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6852 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6853 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6854 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6855 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6856 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6857 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6858 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6859 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6860 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6861 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6862 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6863 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6864 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6865 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6866 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6867 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6868 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6869 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6870 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6871 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6872 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6873 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6874 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6875 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6876 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6877 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6878 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6881 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 6889 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 6890 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations CAMSHAFT POSITION SENSOR The Camshaft Position Sensor (CMP) is located on the top rear center of engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6899 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6900 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6915 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6916 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6917 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6918 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6919 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6920 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6921 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6922 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6923 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6924 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6925 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6926 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6927 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6928 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6929 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6930 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6931 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6932 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6933 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6934 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6964 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6965 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6966 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 6976 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 6977 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations SEO Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 6984 Left Side Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 6985 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 6986 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 6987 2. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6998 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 Crankshaft Position (CKP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 7069 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 7072 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 7073 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel System (Cab Chassis) Fuel Level Sensor: Description and Operation Fuel System (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (I/P) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the powertrain control module (PCM). The PCM calculates the total fuel level in both tanks. The instrument panel (I/P) fuel gage displays the total fuel level in both fuel tanks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel System (Cab Chassis) > Page 7079 Fuel Level Sensor: Description and Operation Fuel System (Pickup and Utility) FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 7082 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 7083 1. Install the fuel level sensor. 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 7084 4. Install the fuel level sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 7085 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 44402 Fuel Tank Sending Unit Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect fuel lines from the sending unit, if required. 3. Using J 44402, remove the sending unit lock ring. 4. Remove the sending unit and seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 5. Clean the sending unit sealing surfaces. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 7086 assure that the fuel strainer does not block full travel of the float arm. 1. Install a NEW sending unit seal. 2. Align the tab, and install the sending unit. 3. Using J 44402, install the sending unit lock ring. 4. Connect fuel lines to the sending unit, if required. 5. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 7090 Fuel Tank Pressure (FTP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 7091 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 7092 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 7096 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 7097 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 7098 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7104 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7117 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7118 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7119 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7120 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7121 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7122 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7123 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7124 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7125 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7126 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7136 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7137 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7138 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7139 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7140 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7141 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7142 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7143 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7144 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7145 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7146 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7147 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7148 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7149 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7150 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7151 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7152 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7153 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7154 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7155 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7156 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7157 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7158 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7159 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7160 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7161 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7162 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7163 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7164 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7165 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7166 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7167 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7168 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7169 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7170 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7171 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7172 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7173 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7174 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7179 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7180 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7181 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 7182 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 7183 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 7184 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Top Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 7188 Manifold Absolute Pressure (MAP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 7189 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 7190 1. Install the MAP sensor (1). 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required ^ J41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 7197 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J41712 or equivalent, install the oil pressure sensor. Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 7206 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 7212 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 7213 HO2S Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7216 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7217 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7218 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7219 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7220 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7221 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7222 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7223 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7224 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7225 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7226 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7227 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7228 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7229 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7230 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7231 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7232 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7240 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7241 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7242 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7243 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7247 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7248 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7256 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7257 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7258 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7259 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7261 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7262 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7263 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7264 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7265 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7266 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7267 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7268 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7269 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7276 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7277 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7278 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7279 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7280 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7281 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7282 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7283 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7290 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7291 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7292 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7293 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7294 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7295 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7298 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7299 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7300 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7301 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7302 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7303 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 7304 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 7309 Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 7312 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 7315 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 7316 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 7317 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 7318 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 7319 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 7324 Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 7327 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 7330 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 7331 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 7332 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 7333 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 7334 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Precautions Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 7340 Catalytic Converter: Service and Repair Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) Removal Procedure 1. Raise and suitably support the vehicle. 2. If equipped, unclip the oxygen sensor connection from the floor reinforcement. 3. Disconnect the oxygen sensor electrical connector. 4. Remove the oxygen sensor clips from the frame. 5. Disconnect the connector position assurance (CPA) retainers. 6. Disconnect the oxygen sensor electrical connectors. 7. Unclip the oxygen sensors electrical connectors from the following: ^ Hose clip ^ Transmission crossmember 8. Disconnect the CPA retainers. 9. Disconnect the oxygen sensor electrical connectors (1, 2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 7341 10. Remove the left exhaust manifold pipe nuts. 11. Remove the right exhaust manifold pipe nuts. 12. Remove the exhaust muffler nuts. 13. Remove the catalytic converter. 14. If necessary, remove the oxygen sensors. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 7342 1. If necessary, install the oxygen sensors. 1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. 2. Install the oxygen sensors. Tighten the sensors to 42 Nm (31 ft. lbs.). 2. Install the catalytic convertor. 3. Install NEW exhaust manifold pipe seals to the exhaust manifolds. 4. Install the right exhaust manifold pipe nuts until snug. 5. Install the left exhaust manifold pipe nuts until snug. 6. Tighten the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 7. Install the exhaust muffler nuts. Tighten the nuts to 40 Nm (30 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 7343 8. Connect the oxygen sensor electrical connectors (1, 2). 9. Connect the CPA retainers. 10. Clip the oxygen sensors electrical connectors to the following: ^ Hose clip ^ Transmission crossmember 11. Connect the oxygen sensor electrical connectors. 12. Connect the CPA retainers. 13. Install the clip around the engine harness and the oxygen sensor pigtail. 14. Connect the oxygen sensor electrical connector. 15. If equipped, clip the oxygen sensor connection to the floor reinforcement. 16. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7353 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7354 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7355 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7356 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7362 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7363 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7364 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7365 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Right Side Of The Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 7369 Left Side Of The Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 7370 Top Of Engine Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 7371 Evaporative Emission (EVAP) Canister Purge Solenoid Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 7372 Canister Purge Solenoid: Description and Operation EVAP PURGE SOLENOID VALVE The EVAP purge solenoid valve controls the flow of vapors from the EVAP system to the intake manifold. The purge solenoid valve opens when commanded ON by the control module. This normally closed valve is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The valve will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 7373 Canister Purge Solenoid: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Remove the evaporative emission (EVAP) line from the canister purge solenoid, perform the following: 1. Push the large size white retainer portion in. 2. Push down, while pulling up slightly in order the disengage the tube. 3. Disconnect the EVAP canister purge solenoid electrical connector (1). 4. Remove the EVAP canister purge solenoid bolt (2). 5. Remove the EVAP canister purge solenoid (3) and insulator (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 7374 INSTALLATION PROCEDURE 1. Install the insulator (1) onto the EVAP canister purge solenoid (3). 2. Install the EVAP canister purge solenoid (3). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EVAP canister purge solenoid bolt (2). Tighten the bolt to 10.5 N.m (93 lb in). 4. Connect the EVAP canister purge solenoid electrical connector (1). 5. Install the EVAP line to the canister purge solenoid (1). 6. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7383 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7384 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7385 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7386 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7392 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7393 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7394 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7395 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7404 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7405 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7406 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7407 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7413 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7414 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7415 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7416 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7425 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7426 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7427 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7428 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7434 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7435 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7436 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 7437 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Check Valve: > 03-03-10-002B > Nov > 05 > Wheels - Correct Hub Cap Installation Procedure Wheel Cover: All Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Check Valve: > 03-03-10-002B > Nov > 05 > Wheels - Correct Hub Cap Installation Procedure > Page 7443 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Check Valve: > 05-03-10-002 > Mar > 05 > Wheels - Hubcaps Loose/Rattling Wheel Cover: All Technical Service Bulletins Wheels - Hubcaps Loose/Rattling Info - Availability of New Functional Nut Caps For Steel Wheels # 05-03-10-002 - (Mar 21, 2005) Models: 2005 Chevrolet Silverado Models 2005 GMC Sierra Models with Steel Wheels Some vehicles may exhibit a condition of loose or rattling wheel hubcaps, especially on the front positions. This may be the result of brake heat distortion of the functional nut caps on the wheels. If this condition is encountered, only the functional nut caps in the hubcap assembly should be replaced, NOT the entire hubcap assembly. New functional nut caps, P/N 9596657, are now available. These new caps consist of more heat resistant material and are less susceptible to heat distortion. The new functional nut caps are dark gray in color. The original caps are black. Therefore, ALL functional nut caps on the vehicle must be replaced (24 functional nut caps on 6 bolt vehicles and 32 functional nut caps on 8 bolt vehicles). The old (black) functional nut caps should be snapped out of the hubcaps, and the new (dark gray) functional nut caps snapped back into place. When installing the hubcaps back on the vehicle, refer to Corporate Bulletin Number 03-03-10-002A. Use of Correct Installation Procedure for Loose Hubcap Assembly for the correct procedure for tightening the nut caps. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Check Valve: > 03-03-10-002B > Nov > 05 > Wheels - Correct Hub Cap Installation Procedure > Page 7453 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations Canister Vent Valve: Locations Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 7462 Evaporative Emission (EVAP) Canister Vent Solenoid Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 7463 Evaporative Emission (EVAP) Canister Vent Solenoid Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 7464 Canister Vent Valve: Description and Operation EVAP VENT SOLENOID VALVE The EVAP vent solenoid valve controls fresh airflow into the EVAP canister. The valve is normally open. The control module commands the valve ON, closing the valve during some EVAP tests, allowing the system to be tested for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > EVAP Canister Vent Solenoid Valve Replacement (Pickup) Canister Vent Valve: Service and Repair EVAP Canister Vent Solenoid Valve Replacement (Pickup) EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the harness clip from the canister vent solenoid (CVS) line. 3. Disconnect the CVS electrical connector. 4. If the vehicle is equipped with a 6 ft box, disconnect the EVAP CVS line from the canister. 5. Remove the CVS clip from the frame crossmember. 6. Push in the retainer and remove the CVS from the fuel tank clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > EVAP Canister Vent Solenoid Valve Replacement (Pickup) > Page 7467 7. If the vehicle is equipped with a 8 ft box, disconnect the EVAP CVS line from the canister. 8. Remove the CVS clip from the frame crossmember. 9. Push in the retainer and remove the CVS from the fuel tank clip. INSTALLATION PROCEDURE 1. If the vehicle is equipped with a 8 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 8 ft box, the CVS line is routed below the frame crossmember. 2. Install the CVS clip to the frame crossmember. 3. Connect the EVAP CVS line to the canister. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > EVAP Canister Vent Solenoid Valve Replacement (Pickup) > Page 7468 4. If the vehicle is equipped with a 6 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 6 ft box, the CVS line is routed above the frame crossmember. 5. Install the CVS clip to the frame crossmember. 6. Connect the EVAP CVS line to the canister. 7. Connect the CVS electrical connector. 8. Install the harness clip to the canister vent solenoid (CVS) line. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > EVAP Canister Vent Solenoid Valve Replacement (Pickup) > Page 7469 Canister Vent Valve: Service and Repair EVAP Canister Vent Solenoid Valve Replacement (1500 Crew Cab) EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the canister vent solenoid (CVS) electrical connector (1). 3. Remove the CVS bracket bolt. 4. Disconnect the CVS line from the evaporative emission (EVAP) canister. 5. Remove the CVS from the vehicle. 6. If necessary, remove the CVS from the CVS bracket. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > EVAP Canister Vent Solenoid Valve Replacement (Pickup) > Page 7470 1. If necessary, install the CVS to the CVS bracket. 2. Install the CVS to the vehicle. Ensure the locator tab is inserted into the frame hole. 3. Connect the CVS line to the canister. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CVS bracket bolt. Tighten the bolt to 12 N.m (106 lb in). 5. Connect the CVS electrical connector (1). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > EVAP Canister Vent Solenoid Valve Replacement (Pickup) > Page 7471 Canister Vent Valve: Service and Repair EVAP Canister Vent Solenoid Valve Replacement (Cab/Chassis) EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT (CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean all evaporative emission (EVAP) connections and surrounding areas before disconnecting the line in order to avoid possible EVAP system contamination. 1. Disconnect the EVAP canister vent solenoid (CVS) electrical connector (1). 2. Remove the EVAP CVS valve bracket bolt (1). 3. Remove the EVAP CVS line from the clips on the fuel tank. 4. Remove the CVS valve and line. 5. Remove the EVAP CVS valve line from the CVS, if necessary. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > EVAP Canister Vent Solenoid Valve Replacement (Pickup) > Page 7472 1. Install the EVAP CVS valve line to the CVS, if necessary. 2. Install the CVS valve and line. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EVAP CVS valve bracket bolt (1). Tighten the bolt to 12 N.m (106 lb in). 4. Install the EVAP CVS line to the clips on the fuel tank. 5. Connect the EVAP CVS electrical connector (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) Evaporative Emissions Hose: Service and Repair EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) EVAPORATIVE EMISSION (EVAP) SYSTEM HOSES/PIPES REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) pipe connections and surrounding area prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the EVAP purge line (2) from the sending unit and retaining clips. 3. Disconnect and remove the EVAP fuel level vent valve (FLVV) line (3) from the sending unit and retaining clips. 4. Cap the fuel feed and EVAP openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed and EVAP lines. 2. Install and connect the EVAP FLVV line (3) line to the sending unit and retaining clips. 3. Install and connect the EVAP purge line (2) to the sending unit and retaining clips. 4. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7477 Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - ENGINE REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Remove the engine sight shield. 2. Disconnect the EVAP tube from the EVAP canister purge solenoid (1). 1. Push the large side white retainer portion in. 2. Push down, while pulling up slightly in order to disengage the tube. 3. Disconnect the EVAP tube from the chassis EVAP pipe (2). 1. Push the large side white retainer portion in. 2. Push down, while pulling up slightly in order to disengage the tube. 4. Remove the EVAP tube. 5. Cap the EVAP canister purge solenoid and EVAP chassis pipe in order to prevent possible EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the EVAP canister purge solenoid and EVAP chassis pipe. 2. Install the EVAP tube. 3. Connect the EVAP tube to the EVAP chassis pipe (2). 4. Connect the EVAP tube to the EVAP purge solenoid (1). 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7478 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Chassis (Pickup) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7479 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 12. Remove the fuel and EVAP bundle nuts. 13. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7480 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7481 5. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 6. Install the fuel line clip(s) to the bracket(s) on the transmission. 7. Install the fuel pipe bracket to the bellhousing stud. 8. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 9. Lower the vehicle. 10. Remove the cap from the fuel rail. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7482 11. Connect the fuel feed line (1) at the engine. 12. Connect the EVAP canister purge tube line (2). 13. Install the fuel fill cap. 14. Connect the negative battery cable. 15. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7483 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Chassis (1500 Crew Cab) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7484 9. Remove the fuel line clips from the brackets on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7485 18. Remove the torsion bar bracket, if equipped with 4WD. 19. Remove the EVAP canister. 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7486 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. 14. Install the fuel line clips to the brackets on the transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7487 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7488 Evaporative Emissions Hose: Service and Repair EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) EVAPORATIVE EMISSION (EVAP) SYSTEM HOSES/PIPES REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) pipe connections and surrounding area prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the EVAP purge line (2) from the sending unit and retaining clips. 3. Disconnect and remove the EVAP fuel level vent valve (FLVV) line (3) from the sending unit and retaining clips. 4. Cap the fuel feed and EVAP openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed and EVAP lines. 2. Install and connect the EVAP FLVV line (3) line to the sending unit and retaining clips. 3. Install and connect the EVAP purge line (2) to the sending unit and retaining clips. 4. Install the fuel tank. Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - ENGINE REMOVAL PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7489 IMPORTANT: Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Remove the engine sight shield. 2. Disconnect the EVAP tube from the EVAP canister purge solenoid (1). 1. Push the large side white retainer portion in. 2. Push down, while pulling up slightly in order to disengage the tube. 3. Disconnect the EVAP tube from the chassis EVAP pipe (2). 1. Push the large side white retainer portion in. 2. Push down, while pulling up slightly in order to disengage the tube. 4. Remove the EVAP tube. 5. Cap the EVAP canister purge solenoid and EVAP chassis pipe in order to prevent possible EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the EVAP canister purge solenoid and EVAP chassis pipe. 2. Install the EVAP tube. 3. Connect the EVAP tube to the EVAP chassis pipe (2). 4. Connect the EVAP tube to the EVAP purge solenoid (1). 5. Install the engine sight shield. EVAP Hoses/Pipes Replacement - Chassis (Pickup) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7490 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the fuel line clips from the brackets on the transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7491 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 12. Remove the fuel and EVAP bundle nuts. 13. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7492 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. 5. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 6. Install the fuel line clip(s) to the bracket(s) on the transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7493 7. Install the fuel pipe bracket to the bellhousing stud. 8. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 9. Lower the vehicle. 10. Remove the cap from the fuel rail. 11. Connect the fuel feed line (1) at the engine. 12. Connect the EVAP canister purge tube line (2). 13. Install the fuel fill cap. 14. Connect the negative battery cable. 15. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. EVAP Hoses/Pipes Replacement - Chassis (1500 Crew Cab) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7494 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7495 9. Remove the fuel line clips from the brackets on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). 18. Remove the torsion bar bracket, if equipped with 4WD. 19. Remove the EVAP canister. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7496 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten the fittings to 25 N.m (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7497 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. 14. Install the fuel line clips to the brackets on the transmission. 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7498 Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. EVAP Hoses/Pipes Replacement - Chassis (Cab/Chassis) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and pressure balance lines from the front tank. 3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7499 4. Disconnect the fuel feed and pressure balance lines from the rear tank. 5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 6. Remove the rear fuel line bundle clip nuts. 7. Remove the rear fuel line bundle. INSTALLATION PROCEDURE 1. Install the rear fuel line bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7500 2. Install the rear fuel line bundle clip nuts. 3. Remove the caps from the fuel and balance lines at the fuel tank. 4. Connect the fuel feed and pressure balance lines from the rear tank. 5. Remove the caps from the fuel and balance lines at the fuel tank. 6. Connect the fuel feed and pressure balance lines from the front tank. 7. Install the fuel fill cap. 8. Connect the negative battery cable. 9. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. EVAP Hoses/Pipes Replacement - Canister/Fuel Tank (Pickup and Cab/Chassis) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CANISTER/FUEL TANK (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean all the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel/EVAP system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP System Hoses/Pipes Replacement (Pickup and Cab/Chassis) > Page 7501 1. Remove the EVAP canister. 2. Remove the EVAP canister line (1). 3. Remove the EVAP canister purge line (2). 4. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel and EVAP lines. 2. Install the EVAP canister purge line (2). 3. Install the EVAP canister line (1). 4. Install the EVAP canister. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation EVAP SERVICE PORT The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid valve and the EVAP canister. The service port is identified by a green colored cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair Crankcase Ventilation Hoses/Pipes Replacement Removal Procedure 1. Remove the engine sight shield. 2. Remove the positive crankcase ventilation (PCV) hose from the intake manifold and valve rocker arm cover. 3. Remove the vent hose from the throttle body and the valve rocker arm cover. 4. Replace the hose as necessary. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 7509 1. Install the hose as necessary. 2. Install the vent hose to the throttle body and the valve rocker arm cover. 3. Install the PCV hose to the intake manifold and valve rocker arm cover. 4. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................385-425 kPa (55-62 psi) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7516 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7517 Steps 1-4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7518 Steps 5-13 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 7523 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. Refer to Fuel Pressure Gage Installation and Removal. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7530 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7531 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7532 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7533 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 7543 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 7549 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 7550 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 7551 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7557 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7558 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7559 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7560 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7561 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7562 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7563 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7564 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7565 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7566 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7567 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7568 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7569 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7570 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7571 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7572 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7573 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7574 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7575 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7576 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7577 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7578 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7579 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7580 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7581 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7582 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7583 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7584 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7585 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7586 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7587 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7588 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7589 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7590 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7591 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7592 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7593 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7594 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7595 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7596 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7597 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7598 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7599 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7600 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7601 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7602 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7603 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7604 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7605 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7606 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7607 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7608 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7609 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7610 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7611 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7612 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7613 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7614 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7615 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7616 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7617 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7618 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7619 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7620 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7621 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7622 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7623 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7624 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7625 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7626 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7627 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7628 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7629 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7630 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7631 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7632 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7633 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 7634 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 7635 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations Fuel Composition Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 7639 Fuel Composition Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 7640 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The fuel composition sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the powertrain control module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing -40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 41/2 percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 7641 Steps 1-5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 7642 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the fuel composition sensor electrical connector. 4. Remove the fuel line retainers (1). 5. Disconnect the fuel composition sensor fuel lines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 7643 6. Remove the fuel composition sensor bracket nuts. 7. Remove the fuel composition sensor. 8. If required, remove the fuel composition sensor bolts and remove the sensor from the bracket. INSTALLATION PROCEDURE 1. If required, install the fuel composition sensor to the bracket and install the bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten bolts to 10 N.m (89 lb in). 2. Install the fuel composition sensor. 3. Install the fuel composition sensor bracket nuts. Tighten nuts to 17 N.m (13 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 7644 4. Connect the fuel composition sensor fuel lines. 5. Install the fuel line retainers (1). 6. Connect the fuel composition sensor electrical connector. 7. Lower the vehicle. 8. Use the following procedure in order to inspect for leaks: - Turn the ignition ON, with the engine OFF, for 2 seconds. - Turn the ignition OFF for 10 seconds. - Turn the ignition ON, with the engine OFF. - Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7649 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7650 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7651 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7652 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7653 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7654 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7655 Fuel: Technical Service Bulletins Fuel System - E85 Refueling Station Information Bulletin No.: 06-06-04-030 Date: May 15, 2006 INFORMATION Subject: Locations of E85 Refueling Stations and Expanded E85 Information Models: 2007 and Prior GM Cars and Trucks Equipped for Flexible Fuel (E85) Attention: U.S. dealers - This bulletin should be directed to the Sales Manager as well as the Service Manager. Copies of this bulletin may be given to customers purchasing or considering the purchase of E85 capable vehicles, and may be left or posted in customer waiting areas. Canadian dealers - This bulletin is intended for the U.S. Market and provides only limited information relevant to the Canadian market. Customer Questions, Concerns and Refueling Locations for E85 Fuel Extensive information on E85 Ethanol based fuels can be found at www.livegreengoyellow.com . This General Motors site contains vital information that anticipates and answers customer questions and concerns about E85 fuel. Part of the information is a useful link that provides the location nationally of all E85 refueling stations. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 7656 Fuel: Specifications FUEL E-85 (85% ETHANOL) The 8th digit of your vehicle identification number (VIN) shows the code letter or number that identifies your engine. You will find the VIN at the top left of the instrument panel. If your vehicle has the 5.3L V8 engine (VIN Code Z only), you may use either regular unleaded gasoline or ethanol fuel containing up to 85% ethanol (E-85); also see Fuel. In all other engines, including the 5.3L V8 (VIN Code T), use only regular unleaded gasoline. Only vehicles that have the 5.3L V8 engine (VIN Code Z) may use 85% ethanol fuel (E-85). General Motors encourages the use of E-85 in vehicles that are designed to use it. The ethanol in E-85 is a "renewable" fuel, meaning it is made from renewable sources such as corn and other crops. Many service stations will not have an 85% ethanol fuel (E-85) pump available. The U. S. Department of Energy has an alternative fuels website (http://www.afdc.doe.gov/refueling_mapsite.shtml) that can help you find E-85 fuel. Those stations that do have E-85 should have a label indicating ethanol content. Do not use the fuel if the ethanol content is greater than 85%. Your vehicle may not operate properly if the ethanol content is greater than 85%. At a minimum, E-85 should meet ASTM Specification D 5798. To insure quick starts in the wintertime, the E-85 fuel must be formulated properly for your climate according to ASTM specification D 5798. If you have trouble starting on E-85, it may be because your E-85 fuel is not properly formulated for your climate. If this happens, switching to gasoline or adding gasoline to your fuel tank may improve starting. Your vehicle is designed to accommodate a mixture of gasoline and E-85 fuel. For good starting and heater efficiency below 32°F (0°C), the fuel mix in the fuel tank should contain no more than 70% ethanol. E-85 has less energy per gallon than gasoline, so you will need to refill your fuel tank more often when using E-85 than when you are using gasoline. Regular unleaded gasoline is recommended when pulling a trailer. For payload capacity with ethanol fuel, see Loading Your Vehicle. NOTICE: Some additives are not compatible with E-85 fuel and may harm your fuel system. Damage caused by additives would not be covered by your new vehicle warranty. Do not use additives with E-85 fuel. Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage would not be covered under your warranty. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > With Special Tool Fuel: Testing and Inspection With Special Tool ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITH SPECIAL TOOL) DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as hesitation, lack of power, stalling, or no start. Excessive concentrations of ethanol used in vehicles not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction. TEST PROCEDURE 1. Test the fuel composition using J 44175 Fuel Composition Tester and J 44175-3 Instruction Manual. 2. If water appears in the fuel sample, perform the following steps: 1. Clean the fuel system. Refer to Fuel System Cleaning. 2. Replace the fuel filter if the vehicle is equipped with a serviceable fuel filter. Fuel Composition Test Examples 3. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the Fuel Composition Test Examples table. 4. If the fuel sample contains more than 15 percent ethanol, add fresh, regular gasoline to the vehicle's fuel tank. 5. Test the fuel composition. 6. If testing shows the ethanol percentage is still more than 15 percent, replace the fuel in the vehicle. Refer to Fuel System Cleaning. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > With Special Tool > Page 7659 Fuel: Testing and Inspection Without Special Tool ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITHOUT SPECIAL TOOL) DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust, or deterioration. Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack or power, stalling, or no start. ALCOHOL IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml specified cylinder with 1 ml graduation marks, fill the cylinder with fuel to the 90 ml mark. 2. Add 10 ml of water in order to bring the total fluid volume to 100 ml and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml. For example, if the volume of the lower layer is increased to 15 ml, this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. PARTICULATE CONTAMINANTS IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. If particles are found clean the entire fuel system thoroughly. Refer to Fuel System Cleaning. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Filler Cap: Customer Interest Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 7668 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 7669 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Filler Cap: All Technical Service Bulletins Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 7675 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 7676 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Cap: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Cap: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 7682 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Cap: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 7688 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 7689 Fuel Filler Cap: Description and Operation FUEL FILLER CAP The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over tightened. To install the cap, turn the cap clockwise until you hear clicks. This indicates that the cap is correctly torqued and fully seated. A built-in device indicates that the fuel filler cap is fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 7695 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. Refer to Fuel Pressure Gage Installation and Removal. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's Fuel Injector: Customer Interest Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7704 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7705 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7706 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7707 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's Fuel Injector: All Technical Service Bulletins Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7713 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7714 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7715 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7716 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 04-06-04-051B > Jan > 06 > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: All Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 04-06-04-051B > Jan > 06 > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: All Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7728 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7729 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7730 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7731 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7732 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7733 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7734 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7735 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7736 Fuel Injector: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7737 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7738 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7739 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7740 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7741 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7742 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7743 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7744 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7772 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7773 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7777 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7778 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7779 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7780 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7781 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7782 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7787 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7788 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7789 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7790 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7791 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7792 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7793 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7794 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7795 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7796 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7797 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7798 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7799 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7800 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7801 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7802 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7803 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7804 Fuel Injector: Connector Views Fuel Injector 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7805 Fuel Injector 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7806 Fuel Injector 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7807 Fuel Injector 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7808 Fuel Injector 5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7809 Fuel Injector 6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7810 Fuel Injector 7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7811 Fuel Injector 8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel System (Cab Chassis) Fuel Injector: Description and Operation Fuel System (Cab Chassis) FUEL INJECTORS The Multec 2 fuel injector assembly is a solenoid device, controlled by the powertrain control module (PCM), that meters pressurized fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) injector solenoid (2) to open a normally closed ball valve (3). This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has 2 machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel System (Cab Chassis) > Page 7814 Fuel Injector: Description and Operation Fuel System (Pickup and Utility) FUEL INJECTORS The fuel injector assembly is a solenoid device controlled by the powertrain control module (PCM) that meters pressurized fuel to a single engine cylinder. The PCM energizes the injector solenoid to open a normally closed ball valve. This allows the fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test FUEL INJECTOR COIL TEST CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS - The use of Dielectric compound GM P/N 12377900 (Canadian P/N 10953529) in the fuel injector electrical connector may eliminate a corrosion condition. - Monitoring the misfire current counters, or misfire graph, may help isolate the fuel injector that is causing the condition. - Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. - Perform the fuel injector coil test within the conditions of the customers concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. - If the fuel injector coil test does not isolate the condition perform the fuel injector balance test. Refer to Fuel Injector Balance Test with Special Tool or Fuel Injector Balance Test with Tech 2. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics TEST Steps 1-7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7817 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool FUEL INJECTOR BALANCE TEST WITH SPECIAL TOOL DESCRIPTION Fuel Injector Balance Test Example (Typical) The scan tool is first used to energize the fuel pump. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7818 Steps 1-5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7819 Steps 6-8 The number below refers to the step number on the diagnostic table. 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Refer to the illustration. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7820 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 FUEL INJECTOR BALANCE TEST WITH TECH 2 DESCRIPTION Fuel Injector Balance Test Example (Typical) The scan tool is first used to energize the fuel pump. The scan tool is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare the flow through each injector. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7821 Steps 1-4 Steps 5-7 The number below refers to the step number on the diagnostic table. 5. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure Fuel Injector: Service and Repair Fuel Injector Cleaning Procedure FUEL INJECTOR CLEANING PROCEDURE TOOLS REQUIRED - J 37287 Fuel Line Shut-Off Adapters - J 35800-A Fuel Injector Cleaner - J 42873-1 3/8 Fuel Line Shut-Off Valve - J 42873-2 5/16 Return Pipe Shut-Off Valve - J 42964-1 3/8 Fuel Pipe Shut-Off Valve - J 42964-2 5/16 Fuel Pipe Shut-Off Valve NOTE: - GM Top-Engine Cleaner is the only injector cleaning agent recommended. Do not use other cleaning agents, as they may contain methanol which can damage fuel system components. - Under NO circumstances should the top engine cleaner be added to the vehicles fuel tank, as it may damage the fuel pump and other system components. - Do not exceed a 10 percent cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the 10 percent cleaning solution concentration does not improve the effectiveness of this procedure. IMPORTANT: - Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have the injectors replaced. - During this procedure you will need a total of 960 ml (32.4 oz) of cleaning solution. That is 2 tanks of solution for the J 35800-A. Other brands of tools may have a different capacity and would therefore require more or less tanks to complete the procedure. You must use all 960 ml (32.4 oz) of solution to ensure complete injector cleaning. 1. Obtain J 35800-A (2). 2. For US dealers, empty 2 pre-measured GM Top-Engine Cleaner containers, 24 ml (0.812 oz) each, GM P/N 12346535, into the J 35800-A. IMPORTANT: Make sure the valve at the bottom of the canister (3) is closed. 3. For Canadian dealers, measure and dispense 48 ml (1.62 oz) of Top-Engine Cleaner, Canadian P/N 992872, into the J 35800-A. 4. If you are using any other brand of tank you will need a total of 96 ml (3.24 oz) of Top-Engine Cleaner mixed with 864 ml (29.16 oz) of regular unleaded gasoline. 5. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool. 6. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. 7. Disconnect the fuel feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped, coming off the fuel rail with J 37287, or J 42964-1, and J 42964-2 or J 42873-1, and J 42873-2 as appropriate for the fuel system. 8. Connect the J 35800-A to the vehicle fuel rail. 9. Pressurize the J 35800-A to 510 kPa (75 psi). 10. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20 minutes. 11. Disconnect J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove J 37287 or J 42964-1, and J 42964-2 or J 42873-1, and J 42873-2 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional 2 minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 7824 15. Repeat steps 1-5 of the Injector Balance Test, and record the fuel pressure drop from each injector. 16. Subtract the lowest fuel pressure drop from the highest fuel pressure drop. If the value is 15 kPa (2 psi) or less, no additional action is required. If the value is greater than 15 kPa (2 psi), replace the injector with the lowest fuel pressure drop. 17. Add one ounce of Port Fuel Injector Cleaner, GM P/N 12345104 (Canadian P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the fuel tank. Instruct the customer to add the reminder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. 18. Advise the customer to change brands of fuel and to add GM Port Fuel Injector Cleaner every 5 000 km (3,000 mi). GM Port Fuel Injector Cleaner contains the same additives that the fuel companies are removing from the fuel to reduce costs. Regular use of GM Port Fuel Injector Cleaner should keep the customer from having to repeat the injector cleaning procedure. 19. Road test the vehicle to verify that the customer concern has been corrected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 7825 Fuel Injector: Service and Repair Fuel Injector Replacement FUEL INJECTOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. IMPORTANT: The engine oil may be contaminated with fuel if the fuel injectors are leaking. 1. Remove the fuel rail. 2. Remove and discard the fuel injector retainer clip (19). 3. Remove the fuel injector (17). 4. Remove and discard the fuel injector retainer clip (1). 5. Remove and discard the fuel injector O-ring seals (2, 4). INSTALLATION PROCEDURE IMPORTANT: When ordering new fuel injectors, you must order the correct injector for the application being serviced. The fuel injector (1) is stamped with a identification part number (2). A four-digit build date code (3) indicates the month (4), day (5), year (6), and shift (7) that built the injector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 7826 1. Lubricate the NEW injector O-ring seals (2, 4) with clean engine oil. 2. Install the NEW injector O-ring seals onto the fuel injector. 3. Install a NEW retainer clip (1) onto the fuel injector. 4. Push the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks on to a flange on the fuel rail injector socket. 5. Install the fuel rail. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Fuel System (Pickup and Utility) Fuel Line Coupler: Description and Operation Fuel System (Pickup and Utility) QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Fuel System (Pickup and Utility) > Page 7831 Fuel Line Coupler: Description and Operation Fuel System (Cab Chassis) QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) QUICK CONNECT FITTING(S) SERVICE (METAL COLLAR) TOOLS REQUIRED - J 41769 Fuel Line Quick Disconnect Tool - J 43178 Fuel Line Disconnect Tool REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the retainer from the fuel feed line to engine quick-connect fitting. 3. If equipped with the 5.3L (L59) engine, remove the retainers from the fuel feed and return line to engine quick-connect fittings. 4. Using compressed air, blow any dirt or debris from around the fitting. CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 7834 5. Using the correct tool from J 41769, insert the tool into the female connector, then push inward in order to release the quick connect locking tabs. 6. If the vehicle is a cab/chassis, it may be necessary to use J 43178 in order to release the quick connect locking tabs. 7. Pull the fuel line connection apart. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 8. Use a clean shop towel in order to wipe off the male connection end. 9. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE 1. Apply a few drops of clean engine oil to the male connection end. CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Push both sides of the fittings together in order to snap the retaining tabs into place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 7835 3. Once installed, pull on both sides of the connection in order to make sure the connection is secure. 4. If equipped with the 5.3L (L59) engine, install the retainers to the fuel feed and return line to engine quick-connect fittings. 5. Install the retainer to the fuel feed line quick-connect fitting. 6. Install the fuel fill cap. 7. Connect the negative battery cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 7836 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) REMOVAL PROCEDURE IMPORTANT: There are several types of plastic fuel and evaporative emission (EVAP) quick connect fittings used on this vehicle. The following instructions apply to all types of plastic quick connect fittings except where indicated. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Using compressed air, blow any dirt or debris from around the quick connect fitting. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 3. Squeeze the plastic quick connect fitting release tabs together to disengage the quick connect fitting. (This step applies to Bartholomew style fittings ONLY) 4. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 7837 5. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting. 6. Pull the quick connect fitting connection apart. INSTALLATION PROCEDURE 1. Apply a few drops of clean engine oil to the male connection end. CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 7838 3. Once installed, pull on both sides of the quick-connect fittings in order to make sure the connection is secure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel System (Cab Chassis) Fuel Pressure Regulator: Description and Operation Fuel System (Cab Chassis) FUEL PRESSURE REGULATOR ASSEMBLY The fuel pressure regulator is a vacuum operated diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure and intake manifold vacuum on the other side. The fuel pressure regulator compensates for changes in intake manifold vacuum by changing the fuel pressure. In this way, the fuel pressure regulator maintains a constant pressure differential across the fuel injectors under all operating conditions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel System (Cab Chassis) > Page 7843 Fuel Pressure Regulator: Description and Operation Fuel System (Pickup and Utility) FUEL PRESSURE REGULATOR The fuel pressure regulator is contained in the fuel sender assembly, and is not servicable. If there is a problem replace the fuel sender assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................385-425 kPa (55-62 psi) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7850 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7851 Steps 1-4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7852 Steps 5-13 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 7857 Fuse Block - Underhood Label The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 7858 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Underhood Fuse Block The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7861 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7862 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7863 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7864 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7865 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7866 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7867 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7868 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7869 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7870 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7871 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7872 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7873 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7874 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7875 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7876 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7877 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7878 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7879 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7880 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7881 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7882 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7883 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7884 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7885 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7886 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7887 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7888 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7889 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7890 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7891 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7892 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7893 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7894 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7895 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7896 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7912 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7913 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7914 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7919 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7920 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7921 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7922 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7923 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7924 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7925 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7926 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7927 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7928 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7929 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7930 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7931 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7932 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7933 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7934 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7935 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7936 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7937 Fuel Pump (FP) Relay - Secondary (w/Dual Tanks) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Fuel System (Pickup and Utility) Fuel Pump Pickup Filter: Description and Operation Fuel System (Pickup and Utility) FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Fuel System (Pickup and Utility) > Page 7942 Fuel Pump Pickup Filter: Description and Operation Fuel System (Cab Chassis) FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Fuel System (Pickup and Utility) Fuel Rail: Description and Operation Fuel System (Pickup and Utility) FUEL RAIL ASSEMBLY The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions: - Positions the injectors (3) in the intake manifold - Distributes fuel evenly to the injectors - Integrates the fuel dampener (2) into the fuel metering system Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Fuel System (Pickup and Utility) > Page 7947 Fuel Rail: Description and Operation Fuel System (Cab Chassis) FUEL RAIL ASSEMBLY The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions: - Positions the injectors (3) in the intake manifold - Distributes fuel evenly to the injectors - Integrates the fuel pressure regulator (2) with the fuel metering system Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 7948 Fuel Rail: Service and Repair FUEL RAIL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. IMPORTANT: The L59 E85 fuel rail is comprised of a material that is compatible with fuel that has a concentration of up to 85 percent ethanol. The E85 fuel rail also uses an E85 Denso fuel injectors. Because of this, special procedures will be used in servicing the fuel rail and associated components. The screws that fasten the retaining clips for the crossover pipe to the fuel rails are thread cutting and therefore should NOT be removed from the fuel rail. The fuel rail will be serviced as an entire component. - An 8-digit identification number (1) is located on the fuel rail. Refer to this model identification number if service or part replacement is required. 2. Remove the wire harness bracket nut (2). 3. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1). 4. Disconnect the generator electrical connector (3). 5. Disconnect the following electrical connectors: - Manifold absolute pressure (MAP) sensor (1) - Knock sensor (2) 6. Remove the knock sensor harness connector from the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 7949 7. Remove the connector position assurance (CPA) retainer. 8. Disconnect the following electrical connectors from both sides of the engine: - Main coil (2) - Fuel injectors 9. Remove the harness clips from the fuel rail (1). 10. Reposition the upper engine wire harness aside. 11. Perform the following steps in order to disconnect the fuel injector electrical connectors: 1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 2. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click. 3. Push the tab (1) on the connector in. 4. Disconnect the fuel injector connector electrical connector. 5. Repeat the steps for each injector connector. IMPORTANT: When disconnecting the Multec(R) 2 fuel injector connectors, DO NOT use pliers or other hand tools, as the connector ends may become mangled and be rendered unusable. 12. Remove the positive crankcase ventilation (PCV) hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 7950 13. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. 14. Disconnect the fuel pressure regulator vacuum line. 15. Remove the fuel rail bolts. 16. Remove the fuel rail. NOTE: Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. - Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages. IMPORTANT: Before removal, if necessary, clean the fuel rail assembly with a spray type engine cleaner, use GM X-30A or equivalent. Follow the package instructions. Do not soak fuel rail assembly in any liquid cleaning solvents. 17. Remove the fuel injector lower O-ring seal (4) from each fuel injector, if necessary. 18. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Lubricate the NEW fuel injector lower O-ring seals (4) with clean engine oil. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 7951 2. Install the NEW O-ring seals (4) onto each injector, if necessary. 3. Install the fuel rail. 4. Apply a 5 mm (0.020 in) band of threadlock, GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the fuel rail bolts. 5. Install the fuel rail bolts. NOTE: Refer to the Fastener Notice in Service Precautions. Tighten the bolts to 10 N.m (89 lb in). 6. Connect the fuel pressure regulator vacuum line. 7. Connect the fuel feed and return pipes (1, 2) to the fuel rail. 8. Install the PCV hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 7952 9. Perform the following steps in order to connect the fuel injector electrical connectors. 1. Install the connectors to their corresponding injectors to ensure correct reassembly. 2. Connect the fuel injector electrical connector. 3. Push the CPA retainer (2) in the connector in 1 click. 4. Repeat the steps for each injector electrical connector. 10. Position the engine wire harness. 11. Connect the following electrical connectors to both sides of the engine: - Main coil (2) - Fuel injectors 12. Install the harness clips to the fuel rail (1). 13. Install the CPA retainers. 14. Connect the following electrical connectors: - MAP sensor (1) - Knock sensor (2) 15. Install the knock sensor harness connector to the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 7953 16. Connect the EVAP purge solenoid electrical connector (1). 17. Connect the generator electrical connector (3). 18. Install the wire harness bracket nut (2). Tighten the nut to 5 N.m (44 lb in). 19. Tighten the fuel fill cap. 20. Connect the negative battery cable. 21. Use the following procedure in order to inspect for leaks: 0. Turn the ignition ON, with the engine OFF, for 2 seconds. 1. Turn the ignition OFF for 10 seconds. 2. Turn the ignition ON, with the engine OFF. 3. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7958 9. Remove the fuel line clip from the bracket on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7959 18. Remove the torsion bar bracket, if equipped with 4WD. 19. Remove the EVAP canister. 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7960 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. 14. Install the fuel line clip to the bracket on the transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7961 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7962 Fuel Return Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (PICKUP AND CAB/CHASSIS ) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. 3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7963 Fuel Return Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (1500 Crew Cab) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed (1) line from the sending unit and retaining clips. 3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7964 Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Pickup) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7965 9. Remove the fuel line clip from the bracket on the transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly. 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7966 18. If equipped with 4WD, remove the torsion bar bracket. 19. Disconnect the fuel and EVAP lines at the fuel tank. 20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 21. Remove the fuel and EVAP bundle clip nuts. 22. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7967 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. 5. If equipped with 4WD, install the torsion bar bracket. 6. Install the EHCU (1). 7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 8. Connect the brake lines to the BPMV. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7968 Tighten the fittings to 25 N.m (18 lb ft). 9. Connect the chassis electrical harness connectors to the EBCM. 10. Install the transfer case harness to the clip bracket. 11. Install the clip to the bracket on the frame. 12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 13. Install the fuel line clips to the brackets on the transmission. 14. Install the HO2S sensor connector to the bracket. 15. Install the fuel pipe bracket to the bellhousing stud. 16. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7969 17. Lower the vehicle. 18. Remove the caps from the fuel rail and EVAP line. 19. Connect the fuel feed line (1) at the engine. 20. Connect the EVAP canister purge tube line (2). 21. Install the fuel fill cap. 22. Connect the negative battery cable. 23. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7970 Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7971 9. Remove the fuel line clip from the bracket on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7972 18. Remove the torsion bar bracket, if equipped with 4WD. 19. Remove the EVAP canister. 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7973 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. 14. Install the fuel line clip to the bracket on the transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7974 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (PICKUP AND CAB/CHASSIS ) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7975 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. 3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Fuel Hose/Pipes Assembly Replacement (1500 Crew Cab) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7976 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed (1) line from the sending unit and retaining clips. 3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Fuel Hose/Pipes Replacement - Chassis (Pickup) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7977 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7978 9. Remove the fuel line clip from the bracket on the transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly. 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7979 18. If equipped with 4WD, remove the torsion bar bracket. 19. Disconnect the fuel and EVAP lines at the fuel tank. 20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 21. Remove the fuel and EVAP bundle clip nuts. 22. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7980 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. 5. If equipped with 4WD, install the torsion bar bracket. 6. Install the EHCU (1). 7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 8. Connect the brake lines to the BPMV. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7981 Tighten the fittings to 25 N.m (18 lb ft). 9. Connect the chassis electrical harness connectors to the EBCM. 10. Install the transfer case harness to the clip bracket. 11. Install the clip to the bracket on the frame. 12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 13. Install the fuel line clips to the brackets on the transmission. 14. Install the HO2S sensor connector to the bracket. 15. Install the fuel pipe bracket to the bellhousing stud. 16. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7982 17. Lower the vehicle. 18. Remove the caps from the fuel rail and EVAP line. 19. Connect the fuel feed line (1) at the engine. 20. Connect the EVAP canister purge tube line (2). 21. Install the fuel fill cap. 22. Connect the negative battery cable. 23. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis - Rear) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - REAR) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and pressure balance lines from the front tank. 3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7983 4. Disconnect the fuel feed and pressure balance lines from the rear tank. 5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 6. Remove the rear fuel line bundle clip nuts. 7. Remove the rear fuel line bundle. INSTALLATION PROCEDURE 1. Install the rear fuel line bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7984 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear fuel line bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and balance lines at the fuel tank. 4. Connect the fuel feed and pressure balance lines to the rear tank. 5. Remove the caps from the fuel and balance lines at the fuel tank. 6. Connect the fuel feed and pressure balance lines to the front tank. 7. Install the fuel fill cap. 8. Connect the negative battery cable. 9. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis - Front) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7985 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7986 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 12. Remove the EVAP line from the clips (2) on the fuel tank. 13. Disconnect the quick connect fittings from the EVAP canister. 14. Remove the fuel and EVAP bundle nuts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7987 15. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Connect the quick connect fittings to the EVAP canister. 4. Install the EVAP line to the clips (2) on the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7988 5. Remove the caps from the fuel and EVAP lines. 6. Connect the fuel and EVAP quick connect fittings. 7. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 8. Install the fuel line clips to the brackets on the transmission. 9. Install the fuel pipe bracket to the bellhousing stud. 10. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) > Page 7989 11. Lower the vehicle. 12. Remove the caps from the fuel rail. 13. Connect the EVAP canister purge tube line (2). 14. Connect the fuel feed line (1) at the engine. 15. Install the fuel fill cap. 16. Connect the negative battery cable. 17. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel System (Pickup and Utility) Fuel Supply Line: Description and Operation Fuel System (Pickup and Utility) NYLON FUEL PIPES CAUTION Refer to Fuel and EVAP Pipe Caution in Service Precautions. Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are 3 sizes of nylon pipes used: 9.5 mm (3/8 in) ID for the fuel supply, 7.6 mm (5/16 in) ID for the fuel return, and 12.7 mm (1/2 in) ID for the vent. Heat resistant rubber hose or corrugated plastic conduit protects the sections of the pipes that are exposed to chafing, to high temperatures, or to vibration. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel System (Pickup and Utility) > Page 7994 Fuel Supply Line: Description and Operation Fuel System (Cab Chassis) NYLON FUEL PIPES Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chafing, high temperature, or vibration. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes. Fuel Feed And Return Pipes The fuel feed pipe carries fuel from the fuel tank to the fuel rail assembly. The fuel return pipe carries fuel from the fuel rail assembly back to the fuel tanks. The fuel pipes consist of 2 sections: The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of nylon. - The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. The chassis fuel pipes are constructed of steel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (PICKUP AND CAB/CHASSIS ) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. 3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 7997 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Pickup) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 7998 9. Remove the fuel line clip from the bracket on the transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly. 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 7999 18. If equipped with 4WD, remove the torsion bar bracket. 19. Disconnect the fuel and EVAP lines at the fuel tank. 20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 21. Remove the fuel and EVAP bundle clip nuts. 22. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8000 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. 5. If equipped with 4WD, install the torsion bar bracket. 6. Install the EHCU (1). 7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 8. Connect the brake lines to the BPMV. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8001 Tighten the fittings to 25 N.m (18 lb ft). 9. Connect the chassis electrical harness connectors to the EBCM. 10. Install the transfer case harness to the clip bracket. 11. Install the clip to the bracket on the frame. 12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 13. Install the fuel line clips to the brackets on the transmission. 14. Install the HO2S sensor connector to the bracket. 15. Install the fuel pipe bracket to the bellhousing stud. 16. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8002 17. Lower the vehicle. 18. Remove the caps from the fuel rail and EVAP line. 19. Connect the fuel feed line (1) at the engine. 20. Connect the EVAP canister purge tube line (2). 21. Install the fuel fill cap. 22. Connect the negative battery cable. 23. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8003 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis Front) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8004 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 12. Remove the EVAP line from the clips (2) on the fuel tank. 13. Disconnect the quick connect fittings from the EVAP canister. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8005 14. Remove the fuel and EVAP bundle nuts. 15. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8006 3. Connect the quick connect fittings to the EVAP canister. 4. Install the EVAP line to the clips (2) on the fuel tank. 5. Remove the caps from the fuel and EVAP lines. 6. Connect the fuel and EVAP quick connect fittings. 7. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 8. Install the fuel line clips to the brackets on the transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8007 9. Install the fuel pipe bracket to the bellhousing stud. 10. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 11. Lower the vehicle. 12. Remove the caps from the fuel rail. 13. Connect the EVAP canister purge tube line (2). 14. Connect the fuel feed line (1) at the engine. 15. Install the fuel fill cap. 16. Connect the negative battery cable. 17. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8008 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis Rear) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - REAR) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and pressure balance lines from the front tank. 3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 4. Disconnect the fuel feed and pressure balance lines from the rear tank. 5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8009 6. Remove the rear fuel line bundle clip nuts. 7. Remove the rear fuel line bundle. INSTALLATION PROCEDURE 1. Install the rear fuel line bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear fuel line bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8010 3. Remove the caps from the fuel and balance lines at the fuel tank. 4. Connect the fuel feed and pressure balance lines to the rear tank. 5. Remove the caps from the fuel and balance lines at the fuel tank. 6. Connect the fuel feed and pressure balance lines to the front tank. 7. Install the fuel fill cap. 8. Connect the negative battery cable. 9. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8011 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (PICKUP AND CAB/CHASSIS ) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. 3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Fuel Hose/Pipes Replacement - Chassis (Pickup) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8012 possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8013 9. Remove the fuel line clip from the bracket on the transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly. 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8014 18. If equipped with 4WD, remove the torsion bar bracket. 19. Disconnect the fuel and EVAP lines at the fuel tank. 20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 21. Remove the fuel and EVAP bundle clip nuts. 22. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8015 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines at the fuel tank. 4. Connect the fuel and EVAP quick connect fittings. 5. If equipped with 4WD, install the torsion bar bracket. 6. Install the EHCU (1). 7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 8. Connect the brake lines to the BPMV. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8016 Tighten the fittings to 25 N.m (18 lb ft). 9. Connect the chassis electrical harness connectors to the EBCM. 10. Install the transfer case harness to the clip bracket. 11. Install the clip to the bracket on the frame. 12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 13. Install the fuel line clips to the brackets on the transmission. 14. Install the HO2S sensor connector to the bracket. 15. Install the fuel pipe bracket to the bellhousing stud. 16. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8017 17. Lower the vehicle. 18. Remove the caps from the fuel rail and EVAP line. 19. Connect the fuel feed line (1) at the engine. 20. Connect the EVAP canister purge tube line (2). 21. Install the fuel fill cap. 22. Connect the negative battery cable. 23. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis - Front) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8018 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8019 12. Remove the EVAP line from the clips (2) on the fuel tank. 13. Disconnect the quick connect fittings from the EVAP canister. 14. Remove the fuel and EVAP bundle nuts. 15. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8020 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel and EVAP bundle nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Connect the quick connect fittings to the EVAP canister. 4. Install the EVAP line to the clips (2) on the fuel tank. 5. Remove the caps from the fuel and EVAP lines. 6. Connect the fuel and EVAP quick connect fittings. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8021 7. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 8. Install the fuel line clips to the brackets on the transmission. 9. Install the fuel pipe bracket to the bellhousing stud. 10. Install the fuel pipe bracket nut. Tighten the nut to 10 N.m (89 lb in). 11. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8022 12. Remove the caps from the fuel rail. 13. Connect the EVAP canister purge tube line (2). 14. Connect the fuel feed line (1) at the engine. 15. Install the fuel fill cap. 16. Connect the negative battery cable. 17. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis - Rear) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - REAR) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and pressure balance lines from the front tank. 3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 4. Disconnect the fuel feed and pressure balance lines from the rear tank. 5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8023 6. Remove the rear fuel line bundle clip nuts. 7. Remove the rear fuel line bundle. INSTALLATION PROCEDURE 1. Install the rear fuel line bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear fuel line bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8024 3. Remove the caps from the fuel and balance lines at the fuel tank. 4. Connect the fuel feed and pressure balance lines to the rear tank. 5. Remove the caps from the fuel and balance lines at the fuel tank. 6. Connect the fuel feed and pressure balance lines to the front tank. 7. Install the fuel fill cap. 8. Connect the negative battery cable. 9. Perform the following procedure in order to inspect for leaks. 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8025 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8026 9. Remove the fuel line clip from the bracket on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Thoroughly wash all contaminants from around the EHCU. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). 18. Remove the torsion bar bracket, if equipped with 4WD. 19. Remove the EVAP canister. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8027 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten the fittings to 25 N.m (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8028 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. 14. Install the fuel line clip to the bracket on the transmission. 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8029 Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Fuel Hose/Pipes Assembly Replacement (1500 Crew Cab) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed (1) line from the sending unit and retaining clips. 3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Assembly Replacement (Pickup and Cab/Chassis ) > Page 8030 INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Cab/Chassis - Front) Fuel Filler Hose: Service and Repair Filler Tube Replacement (Cab/Chassis - Front) FILLER TUBE REPLACEMENT (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. If equipped with a rear auxiliary tank, disconnect the fuel and evaporative emission (EVAP) quick connect fittings. 3. Cap the fuel feed and EVAP pipes in order to prevent possible system contamination. 4. Loosen the fuel fill pipe clamp (2) at the tank. 5. Loosen the vent pipe clamp (1) at the tank. 6. Remove the fuel fill pipe and vent pipe from the tank. 7. Cap the fuel and vent openings in the tank in order to prevent possible system contamination. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Cab/Chassis - Front) > Page 8036 1. Remove the caps from the fuel and vent openings in the tank. 2. Install the fuel fill pipe and vent pipe to the tank. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the vent pipe clamp (1) at the tank. 4. Tighten the fuel fill pipe clamp (2) at the tank. Tighten the clamps to 2.5 N.m (22 lb in). 5. Remove the caps from the fuel feed and EVAP pipes. 6. If equipped with a rear auxiliary tank, connect the fuel and EVAP quick connect fittings. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Cab/Chassis - Front) > Page 8037 Fuel Filler Hose: Service and Repair Filler Tube Replacement (Cab/Chassis - Rear) FILLER TUBE REPLACEMENT (CAB/CHASSIS - REAR) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Loosen the fuel fill pipe hose clamp (2) at the tank. 3. Loosen the fuel vent pipe hose clamp (1) at the tank. 4. Remove the fuel fill and vent hoses from the tank. INSTALLATION PROCEDURE 1. Install the fuel fill and vent hoses to the tank. 2. Tighten the fuel vent pipe hose clamp (1) at the tank. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the fuel fill pipe hose clamp (2) at the tank. Tighten the clamps to 2.5 N.m (22 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Cab/Chassis - Front) > Page 8038 Fuel Filler Hose: Service and Repair Filler Tube Replacement (Pickup) FILLER TUBE REPLACEMENT (PICKUP) REMOVAL PROCEDURE 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Vehicle Lifting. 5. Remove the fuel tank fill pipe ground wire bolt (1). 6. Remove the fuel tank fill pipe ground wire (3) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Cab/Chassis - Front) > Page 8039 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 11. Disconnect the recirculation line from the sending unit. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Cab/Chassis - Front) > Page 8040 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the recirculation line to the sending unit. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 N.m (22 lb in). 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. 7. Position the fuel tank fill pipe ground wire and chassis harness ground wire (2). 8. Install the fuel tank fill pipe ground wire (3) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (1). Tighten the bolt to 9 N.m (80 lb in). 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Cab/Chassis - Front) > Page 8041 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 N.m (20 lb in). 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 N.m (20 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Cab/Chassis - Front) > Page 8042 Fuel Filler Hose: Service and Repair Filler Tube Replacement (1500 Crew Cab) FILLER TUBE REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Partially raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the fuel tank fill pipe ground wire bolt. 6. Remove the fuel tank fill pipe ground wire from the frame. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Cab/Chassis - Front) > Page 8043 7. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 8. Disconnect the recirculation line quick connect fitting at the tank. 9. Remove the fuel tank fill pipe. 10. Cap the opening on the fuel tank in order to prevent possible system contamination. INSTALLATION PROCEDURE 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the recirculation line quick connect fitting at the tank. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 N.m (22 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Cab/Chassis - Front) > Page 8044 5. Position the fuel tank fill pipe ground wire to the frame. Ensure the anti-rotation tab is positioned correctly. 6. Install the fuel tank fill pipe ground wire bolt. Tighten the bolt to 9 N.m (80 lb in). 7. Lower the vehicle. 8. Install the fuel tank filler housing. 9. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the bolts to 2.3 N.m (20 lb in). 10. Install the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). Tighten the screws to 2.3 N.m (20 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams Fuel Pump/Sender Assembly - Primary Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 8048 Fuel Pump/Sender Assembly - Secondary Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System (Pickup and Utility) Fuel Gauge Sender: Description and Operation Fuel System (Pickup and Utility) FUEL SENDER ASSEMBLY The front fuel sender on dual tank applications consists of the following major components: - The fuel level sensor - The fuel tank fuel pump module - The fuel strainer - The fuel filter The rear fuel sender on dual tank applications consists of the following major components: - The fuel level sensor (4) - The FTP sensor (1) - The rear fuel pump (2) The fuel sender assembly on single tank applications consists of the following major components: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System (Pickup and Utility) > Page 8051 - The fuel level sensor - The fuel tank pressure (FTP) sensor - The fuel tank fuel pump module - The fuel strainer - The fuel filter Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel System (Pickup and Utility) > Page 8052 Fuel Gauge Sender: Description and Operation Fuel System (Cab Chassis) FUEL SENDER ASSEMBLY The fuel sender assembly consists of the following major components: - The fuel sender assembly (2) - The fuel strainer (3) - The fuel pump (4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 8053 Fuel Gauge Sender: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 44402 Fuel Tank Sending Unit Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect fuel lines from the sending unit, if required. 3. Using J 44402, remove the sending unit lock ring. 4. Remove the sending unit and seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 5. Clean the sending unit sealing surfaces. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 8054 1. Install a NEW sending unit seal. 2. Align the tab, and install the sending unit. 3. Using J 44402, install the sending unit lock ring. 4. Connect fuel lines to the sending unit, if required. 5. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Tank Vent: Customer Interest Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 8063 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 8064 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Tank Vent: All Technical Service Bulletins Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 8070 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 8071 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair Fuel Tank Unit: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 44402 Fuel Tank Sending Unit Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect fuel lines from the sending unit, if required. 3. Using J 44402, remove the sending unit lock ring. 4. Remove the sending unit and seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 5. Clean the sending unit sealing surfaces. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Page 8075 1. Install a NEW sending unit seal. 2. Align the tab, and install the sending unit. 3. Using J 44402, install the sending unit lock ring. 4. Connect fuel lines to the sending unit, if required. 5. Install the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 8081 Fuse Block - Underhood Label The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 8082 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Underhood Fuse Block The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8089 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8090 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8091 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8092 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8093 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8094 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8095 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8096 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8097 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8098 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8099 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8100 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8101 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8102 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8103 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8104 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8105 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8106 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8107 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8108 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8109 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8110 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8111 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8112 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8113 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8114 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8115 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8116 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8117 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8118 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8119 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8120 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8121 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8122 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8123 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8124 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8125 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8126 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8127 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8128 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8129 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8130 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8131 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8132 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8133 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8134 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8135 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8136 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8137 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8138 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8139 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8140 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8141 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8142 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8143 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8144 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8145 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8146 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8147 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8148 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8149 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8150 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8151 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8152 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8153 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8154 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8155 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8156 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8157 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8158 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8159 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8160 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8161 Fuel Pump (FP) Relay - Secondary (w/Dual Tanks) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair Resonator: Service and Repair AIR CLEANER RESONATOR OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the clamp and separate the air cleaner outlet duct at the mass air flow/intake air temperature (MAF/IAT) sensor. 2. Loosen the clamp and separate the air cleaner outlet duct from the throttle body. 3. Remove the radiator inlet hose clamp from the outlet duct. 4. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the air cleaner outlet duct. 2. Install the air cleaner outlet duct to the throttle body. 3. Install the air cleaner outlet duct to MAF/IAT sensor. 4. Install the radiator inlet hose clamp to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 5. Tighten the air cleaner outlet duct clamps. Tighten the clamps to 4 N.m (35 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8169 Accelerator Pedal Position Sensor: Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8170 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8171 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 8172 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Induction Components Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8178 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8179 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8180 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8181 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8182 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8183 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8184 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8185 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8186 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8187 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8188 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8189 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8190 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8193 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8194 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8195 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8196 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8197 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8198 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8199 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8200 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8201 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8202 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8203 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8204 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8205 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8206 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8207 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8208 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8209 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8210 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8211 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8212 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8213 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8214 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8215 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8216 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8217 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8218 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8219 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8220 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8221 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8222 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8223 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8224 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8225 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8226 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8227 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8228 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8229 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8230 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8231 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8232 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8233 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8234 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8235 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8236 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8237 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8238 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8239 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8240 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8241 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8242 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8243 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8244 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8245 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8246 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8247 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8248 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8249 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8250 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8251 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8252 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8253 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8254 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 8255 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 8256 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations Fuel Composition Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 8260 Fuel Composition Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 8261 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The fuel composition sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the powertrain control module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing -40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 41/2 percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 8262 Steps 1-5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 8263 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the fuel composition sensor electrical connector. 4. Remove the fuel line retainers (1). 5. Disconnect the fuel composition sensor fuel lines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 8264 6. Remove the fuel composition sensor bracket nuts. 7. Remove the fuel composition sensor. 8. If required, remove the fuel composition sensor bolts and remove the sensor from the bracket. INSTALLATION PROCEDURE 1. If required, install the fuel composition sensor to the bracket and install the bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten bolts to 10 N.m (89 lb in). 2. Install the fuel composition sensor. 3. Install the fuel composition sensor bracket nuts. Tighten nuts to 17 N.m (13 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Locations > Page 8265 4. Connect the fuel composition sensor fuel lines. 5. Install the fuel line retainers (1). 6. Connect the fuel composition sensor electrical connector. 7. Lower the vehicle. 8. Use the following procedure in order to inspect for leaks: - Turn the ignition ON, with the engine OFF, for 2 seconds. - Turn the ignition OFF for 10 seconds. - Turn the ignition ON, with the engine OFF. - Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Diagrams Throttle Body Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Diagrams > Page 8269 Throttle Body: Description and Operation THROTTLE BODY ASSEMBLY The throttle body assembly consists of the throttle body, the throttle position (TP) sensors, and the throttle actuator motor. The throttle body functions similar to a similar to a conventional throttle body with the following exceptions: - An electric motor opens and closes the throttle valve. - The throttle blade is spring loaded in both directions and the default position is slightly open. - There are 2 individual TP sensors within the throttle body assembly. The TP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The TP sensors are used to determine the throttle plate angle. The control module provides each TP sensor a 5-volt reference circuit and a low reference circuit. The TP sensors then provide the control module with signal voltage proportional to throttle plate movement. Both TP sensor signal voltages are low at closed throttle and increase as the throttle opens. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement Throttle Body: Service and Repair Throttle Body Assembly Replacement THROTTLE BODY ASSEMBLY REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. IMPORTANT: DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged. - An 8-digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required. 1. Partially drain the cooling system in order to allow the hose at the throttle body to be removed. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. 2. Remove the air cleaner outlet duct. 3. Remove the engine sight shield 4. Disconnect the throttle actuator motor electrical connector (2). 5. Reposition the coolant air bleed hose clamp at the throttle body. 6. Remove the coolant air bleed hose from the throttle body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 8272 7. Remove the throttle body nuts. 8. Remove the throttle body. 9. Remove and discard the throttle body gasket. INSTALLATION PROCEDURE 1. Install the NEW throttle body gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 8273 2. Install the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the throttle body nuts. Tighten the nuts to 10 N.m (89 lb in). 4. Install the coolant air bleed hose to the throttle body. 5. Position the coolant air bleed hose clamp at the throttle body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 8274 6. Connect the throttle actuator motor electrical connector (2). IMPORTANT: Verify that the throttle actuator motor harness connector and the connector seal are properly installed and not damaged. 7. Install the engine sight shield. 8. Install the air cleaner outlet duct. 9. Refill the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System. 10. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 11. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 12. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 13. Start the engine. 14. Inspect for coolant leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 8275 Throttle Body: Service and Repair Throttle Body Cleaning Procedure THROTTLE BODY CLEANING PROCEDURE 1. Remove the air cleaner intake duct. CAUTION: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. NOTE: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. 2. Inspect the throttle body bore and the throttle plate for deposits. You will need to open the throttle plate in order to inspect all surfaces. NOTE: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product. 4. Install the air cleaner intake duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations CAMSHAFT POSITION SENSOR The Camshaft Position Sensor (CMP) is located on the top rear center of engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8282 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8283 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8284 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8285 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8286 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8287 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8288 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8289 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8290 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8291 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8292 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8293 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8294 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8295 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8296 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8297 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8298 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8299 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8300 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8301 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8302 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8303 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8304 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8305 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8306 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8307 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8308 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8309 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8310 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8311 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8312 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8313 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8314 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8315 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8316 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8317 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8318 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8319 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8320 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8321 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8322 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8323 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8324 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8325 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8326 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8327 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8328 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8329 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8330 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8331 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8332 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8333 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8334 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8335 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8336 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8337 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8338 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8339 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8340 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8341 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8342 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8343 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8344 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8345 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8346 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8347 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8348 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8349 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8350 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8351 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8352 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8353 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8354 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8355 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8356 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8357 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8358 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 8359 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 8360 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8365 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8366 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8367 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8368 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8369 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8370 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8371 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8372 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8373 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8374 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8375 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8376 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8377 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8378 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8379 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8380 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8381 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8385 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8386 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8387 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8388 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8389 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8390 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8396 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8397 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8400 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8401 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8402 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8403 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8404 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8405 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8406 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8407 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8408 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8409 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8410 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8411 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8412 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8413 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8414 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8415 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8416 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8417 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8418 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8419 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8420 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8423 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8424 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8425 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8429 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8430 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8431 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8432 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8433 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8434 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8435 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8436 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8437 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8440 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8441 Crankshaft Position (CKP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 8442 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 8445 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 8446 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. .........................................................1,000 ohms per ft Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 8450 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 8451 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: IMPORTANT: The Melco(R) spark plug wires MUST be used only with the Melco(R) coils and bracket, like wise the Delphi(R) spark plug wires MUST be used only with Delphi(R) coils and bracket. The components are NOT interchangeable. 4. The Melco(R) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(R) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. 6. The Melco(R) (1) ignition coil is a square design. 7. The Delphi(R) (2) ignition coil is a round design. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 8452 8. The Melco(R) ignition coil bracket (1) is a square design. 9. The Delphi(R) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams Ignition Coil: Diagrams Ignition Coil 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8456 Ignition Coil 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8457 Ignition Coil 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8458 Ignition Coil 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8459 Ignition Coil 5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8460 Ignition Coil 6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8461 Ignition Coil 7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8462 Ignition Coil 8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8463 Ignition Coil: Description and Operation IGNITION COILS Each ignition coil has an ignition 1 feed and a ground. The PCM supplies a low reference and an ignition control (IC) circuit. Each ignition coil contains a solid state driver module. The PCM will command the IC circuit ON, this allows the current to flow through the primary coil windings for the appropriate time or dwell. When the PCM commands the IC circuit OFF, this will interrupt current flow through the primary coil windings. The magnetic field created by the primary coil windings will collapse across the secondary coil windings, which induces a high voltage across the spark plug electrodes. The coils are current limited to prevent overloading if the IC current is held high too long. The spark plugs are connected to their respective coils by a short secondary wire. The spark plugs are tipped with iridium for long life and efficiency. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8464 Ignition Coil: Service and Repair IGNITION COIL(S) REPLACEMENT REMOVAL PROCEDURE 1. If equipped with regular production option (RPO) HP2, disconnect the energy storage box (ESB). 2. Remove the spark plug wire from the ignition coil. 3. Disconnect the ignition coil electrical connector. 4. If equipped with regular production option (RPO) HP2, remove the auxiliary heater water pump bracket bolts. 5. Remove the auxiliary heater water pump from the studs, and reposition out of the way. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8465 6. If equipped with RPO HP2, remove the starter/generator control module (SGCM) cover bolts, and cover. 7. Remove the 3-phase cable nuts to the SGCM. 8. Remove the 3-phase cable from the SGCM. 9. If equipped with RPO HP2, remove the 3-phase cable bracket nuts. 10. Remove the 3-phase cable bracket from the studs, and reposition the cable and bracket out of the way. 11. Remove the ignition coil bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8466 12. Remove the ignition coil. INSTALLATION PROCEDURE 1. Install the ignition coil. 2. Install the ignition coil bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 8 N.m (71 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8467 3. If equipped with RPO HP2, position the cable (w/bracket) and install the 3-phase cable bracket to the studs. 4. Install the 3-phase cable bracket nuts. Tighten the nuts to 15 N.m (11 lb ft). 5. If equipped with RPO HP2, install the 3-phase cable to the SGCM. 6. Install the 3-phase cable nuts to the SGCM. Tighten the nuts to 9 N.m (80 lb in). 7. Install the SGCM cover and bolts. Tighten the bolts to 9 N.m (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8468 8. If equipped with RPO HP2, position the auxiliary heater water pump and install it onto the studs. 9. Install the auxiliary heater water pump bracket bolts. Tighten the bolts to 15 N.m (11 lb ft). 10. Connect the ignition coil electrical connector. 11. Install the spark plug wire to the ignition coil. 12. If equipped with RPO HP2, connect the ESB. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The PCM 1 fuse - The ETC/ECM fuse - The INJ 1 fuse - The INJ 2 fuse - The SBA fuse, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 8472 Steps 1-7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 8473 Steps 8-17 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 8474 Steps 18-26 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 8475 Steps 27-31 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8512 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8520 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8521 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8522 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8523 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8524 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8525 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8526 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8542 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8543 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8544 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8545 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8546 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8547 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8548 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8549 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8550 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8551 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8552 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8553 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8554 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8555 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8556 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8557 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8558 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 8559 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 8560 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 8561 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The PCM 1 fuse - The ETC/ECM fuse - The INJ 1 fuse - The INJ 2 fuse - The SBA fuse, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 8566 Steps 1-7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 8567 Steps 8-17 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 8568 Steps 18-26 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 8569 Steps 27-31 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations CAMSHAFT POSITION SENSOR The Camshaft Position Sensor (CMP) is located on the top rear center of engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8576 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8577 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8578 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8579 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8580 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8581 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8582 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8583 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8584 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8585 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8586 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8587 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8588 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8589 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8590 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8591 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8592 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8593 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8594 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8595 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8596 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8597 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8598 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8599 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8600 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8601 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8602 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8603 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8604 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8605 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8606 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8607 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8608 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8609 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8610 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8611 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8612 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8613 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8614 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8615 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8616 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8617 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8618 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8619 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8620 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8621 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8627 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8635 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8636 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8637 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8638 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8639 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8640 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8641 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8642 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8643 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8644 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8645 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8646 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8647 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8648 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8649 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8650 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8651 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8652 Camshaft Position (CMP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 8653 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 8654 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Remove the CMP sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten the bolt to 29 N.m (21 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8659 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8660 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8661 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8662 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8663 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8665 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8666 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8667 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8668 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8671 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8672 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8673 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8674 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8675 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8676 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8677 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8678 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8679 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8680 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8681 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8682 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8683 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8684 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8685 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8686 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8687 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8688 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8689 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8690 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8691 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8692 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8693 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8694 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8695 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8696 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8697 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8698 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8699 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8700 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8701 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8702 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8703 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8704 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8705 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8706 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8707 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8708 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8709 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8710 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8711 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8712 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8713 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8714 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8715 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8716 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8717 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8718 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8719 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8720 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8721 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8722 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8723 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8724 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8725 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8726 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8727 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8728 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8729 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8730 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8731 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8732 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8733 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8734 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8735 Crankshaft Position (CKP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 8736 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 8739 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 8740 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensors Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8746 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8747 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8748 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8749 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8750 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8751 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8752 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8753 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8754 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8755 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8756 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8757 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8758 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8759 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8760 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8761 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8762 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8763 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8764 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8765 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8766 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8767 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8768 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8769 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8770 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8771 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8772 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8773 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8774 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8775 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8776 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8777 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8778 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8779 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8780 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8781 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8782 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8783 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8784 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8785 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8786 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8787 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8788 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8789 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8790 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8791 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8792 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8793 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8794 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8795 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8796 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8797 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8798 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8799 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8800 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8801 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8802 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8803 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8804 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8805 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8806 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8807 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8808 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8809 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8810 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8811 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8812 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8813 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8814 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8815 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8816 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8817 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8818 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8819 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8820 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8821 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8822 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8823 Knock Sensor (KS) - 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 8824 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 8825 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE 1. Install the knock sensors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the sensor to 20 N.m (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 8826 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ............................................ 1.02 mm (0.04 inches) Spark Plug Torque ............................................. ................................................................................................................................... 15 Nm (11 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 8830 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................... AC 25171803 (NGK 12567759) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 8831 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 8832 - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 8833 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 8834 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Spark plug gap: 1.016 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. - Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 5. Install the spark plug wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Pressure Regulating Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8842 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8843 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8844 Pressure Regulating Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 8847 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 8848 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 8849 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Transmission Shift Lock Control Actuator Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 8853 Shift Interlock Solenoid: Description and Operation Automatic Transmission Shift Lock Control Description and Operation Automatic Transmission Shift Lock Control System The automatic transmission shift lock control is a safety device that prevents an inadvertent shift out of PARK when the ignition is ON. The driver must press the brake pedal before moving the shift lever out of the PARK position. The system consists of the following components: ^ The automatic transmission shift lock control solenoid. ^ The automatic transmission shift lock control switch. ^ The park/neutral position switch. With the ignition in the ON position, battery positive voltage is supplied to the park/neutral position switch. When the transmission is in the PARK position the contacts in the park/neutral position switch are closed. This allows current to flow through the switch to the automatic transmission shift lock control switch. The circuit continues through the normally-closed switch to the automatic transmission shift lock control solenoid. The automatic transmission shift lock control solenoid is permanently grounded. This energizes the automatic transmission shift lock control solenoid, locking the shift linkage in the PARK position. When the driver presses the brake pedal the contacts in the automatic transmission shift lock control switch open, causing the automatic transmission shift lock control solenoid to release. This allows the shift lever to move from the PARK position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 8854 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to Restraint Systems Caution in Service Precautions. Disable the Restraint system. Refer to Restraint Systems Disabling and Enabling Zone 3 in Restraint Systems. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 8855 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the Body Control Module. 6. Enable the Restraint systems. Refer to Restraint Systems Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 8860 Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Shift Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8863 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8864 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8865 Shift Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Shift Solenoid: Diagrams 4L60-E/4L65-E 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 8868 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 8869 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 8870 Shift Solenoid: Diagrams 4L80-E/4L85-E 1-2 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 8871 2-3 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8872 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8873 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8874 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8875 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Torque Converter Clutch Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8880 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8881 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8882 Torque Converter Clutch Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Torque Converter Clutch Solenoid: Diagrams 4L60-E/4L65-E Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 8885 Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side (M30)/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 8886 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8887 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector.Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8888 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8889 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8890 ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8891 ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 Transfer Case Actuator: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 8897 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 8898 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 8899 Transfer Case Actuator: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 8900 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 Transfer Case Actuator: Service and Repair NVG 246-NP8 Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield. 2. Remove the front propeller shaft. 3. Disconnect the transfer case switch electrical connector (2). 4. Disconnect the encoder motor electrical connector (7). 5. Remove the encoder motor bolts. 6. Remove the encoder motor. 7. Remove the actuator insulator gasket. 8. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the transfer case at the shift shaft, using a crescent wrench if necessary. ^ When installing the encoder motor, ensure that the encoder motor is indexed correctly and the motor is flat against the transfer case before tightening the bolts. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 8903 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector (7). 6. Connect the transfer case switch electrical connector (2). 7. Install the front propeller shaft. 8. Install the transfer case shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 8904 Transfer Case Actuator: Service and Repair NVG 263-NP1 Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 8905 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation SHIFT INDICATOR The instrument panel cluster (IPC) illuminates the shift indicator when the powertrain control module (PCM) determines that the vehicle should be shifted to the next higher gear. The IPC receives a class 2 message from the PCM requesting illumination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls - Shared Diagnostic Trouble Codes Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 8922 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 8925 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 Control Module: Diagrams NVG 246-NP8 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 8928 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 8929 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 8930 Control Module: Diagrams NVG 263-NP1 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 8931 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 8932 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8935 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8936 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8937 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Automatic Transmission Shift Lock Control Component Views Lower Steering Column Components Lower Steering Column Components 1 - A/T Shift Lock Control Actuator 2 - Steering Column Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 8947 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Fluid Pressure Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8950 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8951 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8952 Fluid Pressure Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 8955 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8956 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8957 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8958 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Remove the remaining valve body bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8959 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8960 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Notice: Refer to Fastener Notice in Service Precautions. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8961 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8962 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Do not install the transmission fluid indicator stop bracket and bolt at this time.Install but do not tighten the valve body bolts which retain only the valve body directly.Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8963 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8964 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8965 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 8970 Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 8973 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 8976 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 8977 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 8978 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 8979 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 8980 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Speed Sensor: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8985 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8986 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 8987 Transmission Speed Sensor: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E Transmission Speed Sensor: Diagrams 4L80-E/4L85-E Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 8990 Automatic Transmission Output Shaft Speed (AT OSS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 8991 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Speed Sensor: Service and Repair 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 8994 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 8995 Transmission Speed Sensor: Service and Repair 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 8996 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 8997 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 8998 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E > Page 9003 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Temperature Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9006 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9007 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9008 Transmission Temperature Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9009 Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 Transmission Speed Sensor: Locations NV 3500 Manual Transmission Component Views Manual Transmission - NV 3500 Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 9015 Transmission Speed Sensor: Locations NV 4500 Manual Transmission Component Views Manual Transmission - NV 4500 Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 9016 Transmission Speed Sensor: Locations ZF S6-650 Manual Transmission Component Views Manual Transmission - ZF S6-650 Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 9019 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 9020 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 9023 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 9024 Transmission Speed Sensor: Service and Repair NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 9025 3. Connect the VSS electrical connector (3).Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 9026 Transmission Speed Sensor: Service and Repair ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. If equipped with the 6.6L engine , disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 9027 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine , connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 Four Wheel Drive Selector Switch: Locations NVG 246-NP8 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 > Page 9033 Four Wheel Drive Selector Switch: Locations NVG 263-NP1 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 Four Wheel Drive Selector Switch: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 9036 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 9037 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 9038 Four Wheel Drive Selector Switch: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 9039 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 9040 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 9041 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Gear Sensor/Switch: Service and Repair NVG 246-NP8 Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to Neutral prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench. 3. Remove and discard 2 screws (2) from the motor cover. 4. Remove and discard 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 9046 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat-tipped screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 9047 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler gear are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 9048 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 9049 Gear Sensor/Switch: Service and Repair NVG 261-NP2 Transfer Case Gear Indicator Switch Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the gear indicator switch electrical connector (2). 3. Remove the gear indicator switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the gear indicator switch. ^ Tighten the switch to 27 Nm (20 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 9050 2. Connect the gear indicator switch electrical connector (2). 3. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 9051 Gear Sensor/Switch: Service and Repair NVG 263-NP1 Encoder Motor Sensor Replacement Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 9052 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 9053 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 9054 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Transfer Case Shift Control Switch Replacement Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 9063 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 9069 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 9081 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 9084 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 9085 Speed Sensor: Service and Repair NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 9086 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 9087 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 9088 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 9089 Speed Sensor: Service and Repair NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 9090 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 9091 Speed Sensor: Service and Repair NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 9092 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade PROM - Programmable Read Only Memory: Recalls Campaign - ECM Software Upgrade Bulletin No.: 06535 Date: August 09, 2006 SYSTEM SOFTWARE UPGRADE Subject: 06535-ON-BOARD DIAGNOSTIC (OBD) SYSTEM SOFTWARE UPGRADE - OBD SYSTEM IMPROVEMENTS (REPROGRAM POWERTRAIN CONTROL MODULE {PCM}) Models: 2004-05 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2004-05 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2004-05 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 8.0 for 2006 or later, broadcast to dealers on August 6, 2006 or TIS 2 Web version 8.0 for 2006 (website version of TIS); and on TIS DVD version 8.0 / 2006 or later, mailed to dealers beginning August 23, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06535 remains 'open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or DVD availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Note: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic head lamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade > Page 9101 are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view Summary screen. 15. Verify that current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade > Page 9102 For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse PROM - Programmable Read Only Memory: Customer Interest Engine, A/T Controls - A/T Shudder/Slip in Reverse TECHNICAL Bulletin No.: 08-07-30-010 Date: February 27, 2008 Subject: 4L60E Automatic Transmission (RPO M30) - Shudder or Slip in Reverse Under Hard Acceleration (Reprogram PCM) Models: 2005-2006 Chevrolet Avalanche, Suburban Tahoe 2005-2007 Chevrolet Silverado Classic 2005-2006 GMC Yukon, Yukon XL 2005-2007 GMC Sierra Classic with 4.8L or 5.3L Engine and 4L60E Automatic Transmission (RPO M30) Condition Some customers may comment on a shudder or slip when engaging reverse on hard acceleration only. This condition is most easily duplicated by shifting to reverse and immediately accelerating very aggressively on level ground less aggressively up a hill or with a heavy load. Correction Important: Ensure the vehicle is equipped with the OEM tire size prior to attempting the below diagnosis. Also, make sure that the rear tires are matching side-to-side in make, size and depth of tread (wear). Mismatched tires can contribute to axle hop that can feel like shudder. Before attempting to duplicate this concern ask the customer if the condition occurs when the vehicle is loaded or has a trailer attached or if the vehicle is unloaded. This condition can also be caused by rear axle hop especially when backing a trailer up a hill. When attempting to duplicate the condition have another person watch the rear tires to verify a possible hop condition. Also when attempting to duplicate the condition allow one second after moving the shift lever to the reverse position before depressing the accelerator pedal. Increasing throttle before one second may result in slip or shudder even though there is not a problem with the transmission as the clutches are not fully filled and applied. If slip or shudder occurs verify that reverse boost can be obtained. Use a line pressure gauge to monitor line pressure and a Tech 2(R) to monitor PSC amperage during the concern and document in a TAC case. Engage D4 raise the engine RPM to 1000 and allow three seconds for line pressure to stabilize. Record the line pressure. Engage reverse raise engine the RPM to 1000 and allow three seconds for line pressure to stabilize and record line pressure again. Reverse pressure should be at least 20 psi (138 kPa) higher than drive pressure. Find an identical vehicle and duplicate the same driving maneuver. If it does exhibit the same symptom this may be an unreasonable driving maneuver and repairs may not be necessary. If another vehicle does not exhibit this concern the PCM should be reprogrammed. A revised transmission calibration has been developed to address these issues. Reprogram the PCM with updated calibration files using the TIS2WEB Service Programming System (SPS) application. As always make sure your Tech 2(R) is updated with the latest software version. Important: These calibrations will be "selectable" and should only be used to correct a customer concern as detailed above. Use of this calibration in a vehicle without these concerns may result in comments of harsh engagement into reverse. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse > Page 9108 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 9113 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-07-30-012 > May > 05 > Engine Controls 4L60E/4L65E A/T, 2-3 Shift Clunk Noise PROM - Programmable Read Only Memory: Customer Interest Engine Controls - 4L60E/4L65E A/T, 2-3 Shift Clunk Noise Bulletin No.: 05-07-30-012 Date: May 09, 2005 TECHNICAL Subject: 4L60-E/4L65-E Automatic Transmission 2-3 Shift Clunk (Reprogram Powertrain Control Module (PCM) Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005 GMC Sierra, Yukon with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission Condition Some customers may comment on a 2-3 shift clunk noise. Typically, this clunk noise is most noticeable when the 2-3 shift occurs under approximately 48 km/h (30 mph). Correction Important: ^ The PCM calibrations may REDUCE but not ELIMINATE the 2-3 shift clunk. ^ This bulletin only applies to the 2005 model year vehicles listed above. ^ As always, make sure your TECH 2(R) is updated with the latest software version. 1. To determine if this calibration will help to reduce 2-3 shift clunk, use the Tech 2 to navigate to the transmission diagnostic section and view the 2-3 shift adapt cells. ^ If the 2-3 adapt cell values are negative, this calibration change will have minimal benefit in reducing the 2-3 shift clunk. ^ If the 2-3 adapt cell values are above approximately + 5 psi, this calibration may provide a reduction in the 2-3 shift clunk. Important: These calibrations also contain the second gear start correction as detailed in bulletin 05-07-30-013. 2. Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 5 or later available May 1, 2005. Refer to Service Programming System (SPS) in Vehicle Control Systems in the appropriate SI Document. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-07-30-012 > May > 05 > Engine Controls 4L60E/4L65E A/T, 2-3 Shift Clunk Noise > Page 9118 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-07-30-013 > May > 05 > Engine Controls 4L60E/4L65E A/T 2nd Gear Start PROM - Programmable Read Only Memory: Customer Interest Engine Controls - 4L60E/4L65E A/T 2nd Gear Start Bulletin No.: 05-07-30-013 Date: May 09, 2005 TECHNICAL Subject: 4L60-E/4L65-E Automatic Transmission Second Gear Start, Lack/Loss of Power When Accelerating From a Stop (Reprogram Powertrain Control Module (PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2004-2005 GMC Savana, Sierra, Yukon 2004-2005 HUMMER H2 with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission Condition Some customers may comment on a slip on launch, low power on a launch or a second gear start when accelerating from a stop. This condition is usually very intermittent, occurring only once in a few thousand miles of driving. A Tech 2 or VDR snapshot of the event may show 2nd gear being commanded for approximately two seconds, then 1st gear commanded as would be expected. Cause This condition may be caused by an intermittent VSS signal, which causes the PCM to command second gear. Important: There are other conditions that can cause the transmission to start in a gear higher than first. The following are a few of these conditions. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. ^ Debris on top of the spacer plate or in the valve body or a leaking shift solenoid can cause a 4L60-E or 4L65-E transmission to start in a gear higher than first. A start in a higher gear caused by any of these conditions typically occurs with much greater frequency. Refer to Service Bulletin 01-07-30-036D or newer for diagnostic information of these conditions. ^ Placing the shift lever in the D2 position will cause a 4L60-E or 4L65-E transmission to start in second gear. Correction Important: ^ This bulletin ONLY applies to 2004-2005 models year vehicles listed above. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. 1. Using a scan tool, check for the presence of DTCs. If DTCs are present, refer to the appropriate SI Document before proceeding with this calibration. Important: These calibrations also contain the 2-3 shift clunk calibration as detailed in bulletin 05-07-30-012. 2. Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 5 or later available May 1, 2005. Refer to Service Programming System (SPS) in Vehicle Control Systems in the appropriate SI Document. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-07-30-013 > May > 05 > Engine Controls 4L60E/4L65E A/T 2nd Gear Start > Page 9123 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls A/T Shudder/Slip in Reverse TECHNICAL Bulletin No.: 08-07-30-010 Date: February 27, 2008 Subject: 4L60E Automatic Transmission (RPO M30) - Shudder or Slip in Reverse Under Hard Acceleration (Reprogram PCM) Models: 2005-2006 Chevrolet Avalanche, Suburban Tahoe 2005-2007 Chevrolet Silverado Classic 2005-2006 GMC Yukon, Yukon XL 2005-2007 GMC Sierra Classic with 4.8L or 5.3L Engine and 4L60E Automatic Transmission (RPO M30) Condition Some customers may comment on a shudder or slip when engaging reverse on hard acceleration only. This condition is most easily duplicated by shifting to reverse and immediately accelerating very aggressively on level ground less aggressively up a hill or with a heavy load. Correction Important: Ensure the vehicle is equipped with the OEM tire size prior to attempting the below diagnosis. Also, make sure that the rear tires are matching side-to-side in make, size and depth of tread (wear). Mismatched tires can contribute to axle hop that can feel like shudder. Before attempting to duplicate this concern ask the customer if the condition occurs when the vehicle is loaded or has a trailer attached or if the vehicle is unloaded. This condition can also be caused by rear axle hop especially when backing a trailer up a hill. When attempting to duplicate the condition have another person watch the rear tires to verify a possible hop condition. Also when attempting to duplicate the condition allow one second after moving the shift lever to the reverse position before depressing the accelerator pedal. Increasing throttle before one second may result in slip or shudder even though there is not a problem with the transmission as the clutches are not fully filled and applied. If slip or shudder occurs verify that reverse boost can be obtained. Use a line pressure gauge to monitor line pressure and a Tech 2(R) to monitor PSC amperage during the concern and document in a TAC case. Engage D4 raise the engine RPM to 1000 and allow three seconds for line pressure to stabilize. Record the line pressure. Engage reverse raise engine the RPM to 1000 and allow three seconds for line pressure to stabilize and record line pressure again. Reverse pressure should be at least 20 psi (138 kPa) higher than drive pressure. Find an identical vehicle and duplicate the same driving maneuver. If it does exhibit the same symptom this may be an unreasonable driving maneuver and repairs may not be necessary. If another vehicle does not exhibit this concern the PCM should be reprogrammed. A revised transmission calibration has been developed to address these issues. Reprogram the PCM with updated calibration files using the TIS2WEB Service Programming System (SPS) application. As always make sure your Tech 2(R) is updated with the latest software version. Important: These calibrations will be "selectable" and should only be used to correct a customer concern as detailed above. Use of this calibration in a vehicle without these concerns may result in comments of harsh engagement into reverse. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse > Page 9129 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign - ECM Software Upgrade Bulletin No.: 06535 Date: August 09, 2006 SYSTEM SOFTWARE UPGRADE Subject: 06535-ON-BOARD DIAGNOSTIC (OBD) SYSTEM SOFTWARE UPGRADE - OBD SYSTEM IMPROVEMENTS (REPROGRAM POWERTRAIN CONTROL MODULE {PCM}) Models: 2004-05 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2004-05 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2004-05 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 8.0 for 2006 or later, broadcast to dealers on August 6, 2006 or TIS 2 Web version 8.0 for 2006 (website version of TIS); and on TIS DVD version 8.0 / 2006 or later, mailed to dealers beginning August 23, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06535 remains 'open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or DVD availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Note: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic head lamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade > Page 9134 are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view Summary screen. 15. Verify that current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade > Page 9135 For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 9140 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-07-30-012 > May > 05 > Engine Controls - 4L60E/4L65E A/T, 2-3 Shift Clunk Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls 4L60E/4L65E A/T, 2-3 Shift Clunk Noise Bulletin No.: 05-07-30-012 Date: May 09, 2005 TECHNICAL Subject: 4L60-E/4L65-E Automatic Transmission 2-3 Shift Clunk (Reprogram Powertrain Control Module (PCM) Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005 GMC Sierra, Yukon with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission Condition Some customers may comment on a 2-3 shift clunk noise. Typically, this clunk noise is most noticeable when the 2-3 shift occurs under approximately 48 km/h (30 mph). Correction Important: ^ The PCM calibrations may REDUCE but not ELIMINATE the 2-3 shift clunk. ^ This bulletin only applies to the 2005 model year vehicles listed above. ^ As always, make sure your TECH 2(R) is updated with the latest software version. 1. To determine if this calibration will help to reduce 2-3 shift clunk, use the Tech 2 to navigate to the transmission diagnostic section and view the 2-3 shift adapt cells. ^ If the 2-3 adapt cell values are negative, this calibration change will have minimal benefit in reducing the 2-3 shift clunk. ^ If the 2-3 adapt cell values are above approximately + 5 psi, this calibration may provide a reduction in the 2-3 shift clunk. Important: These calibrations also contain the second gear start correction as detailed in bulletin 05-07-30-013. 2. Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 5 or later available May 1, 2005. Refer to Service Programming System (SPS) in Vehicle Control Systems in the appropriate SI Document. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-07-30-012 > May > 05 > Engine Controls - 4L60E/4L65E A/T, 2-3 Shift Clunk Noise > Page 9145 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-07-30-013 > May > 05 > Engine Controls - 4L60E/4L65E A/T 2nd Gear Start PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls 4L60E/4L65E A/T 2nd Gear Start Bulletin No.: 05-07-30-013 Date: May 09, 2005 TECHNICAL Subject: 4L60-E/4L65-E Automatic Transmission Second Gear Start, Lack/Loss of Power When Accelerating From a Stop (Reprogram Powertrain Control Module (PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2004-2005 GMC Savana, Sierra, Yukon 2004-2005 HUMMER H2 with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission Condition Some customers may comment on a slip on launch, low power on a launch or a second gear start when accelerating from a stop. This condition is usually very intermittent, occurring only once in a few thousand miles of driving. A Tech 2 or VDR snapshot of the event may show 2nd gear being commanded for approximately two seconds, then 1st gear commanded as would be expected. Cause This condition may be caused by an intermittent VSS signal, which causes the PCM to command second gear. Important: There are other conditions that can cause the transmission to start in a gear higher than first. The following are a few of these conditions. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. ^ Debris on top of the spacer plate or in the valve body or a leaking shift solenoid can cause a 4L60-E or 4L65-E transmission to start in a gear higher than first. A start in a higher gear caused by any of these conditions typically occurs with much greater frequency. Refer to Service Bulletin 01-07-30-036D or newer for diagnostic information of these conditions. ^ Placing the shift lever in the D2 position will cause a 4L60-E or 4L65-E transmission to start in second gear. Correction Important: ^ This bulletin ONLY applies to 2004-2005 models year vehicles listed above. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. 1. Using a scan tool, check for the presence of DTCs. If DTCs are present, refer to the appropriate SI Document before proceeding with this calibration. Important: These calibrations also contain the 2-3 shift clunk calibration as detailed in bulletin 05-07-30-012. 2. Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 5 or later available May 1, 2005. Refer to Service Programming System (SPS) in Vehicle Control Systems in the appropriate SI Document. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-07-30-013 > May > 05 > Engine Controls - 4L60E/4L65E A/T 2nd Gear Start > Page 9150 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls A/T Shudder/Slip in Reverse TECHNICAL Bulletin No.: 08-07-30-010 Date: February 27, 2008 Subject: 4L60E Automatic Transmission (RPO M30) - Shudder or Slip in Reverse Under Hard Acceleration (Reprogram PCM) Models: 2005-2006 Chevrolet Avalanche, Suburban Tahoe 2005-2007 Chevrolet Silverado Classic 2005-2006 GMC Yukon, Yukon XL 2005-2007 GMC Sierra Classic with 4.8L or 5.3L Engine and 4L60E Automatic Transmission (RPO M30) Condition Some customers may comment on a shudder or slip when engaging reverse on hard acceleration only. This condition is most easily duplicated by shifting to reverse and immediately accelerating very aggressively on level ground less aggressively up a hill or with a heavy load. Correction Important: Ensure the vehicle is equipped with the OEM tire size prior to attempting the below diagnosis. Also, make sure that the rear tires are matching side-to-side in make, size and depth of tread (wear). Mismatched tires can contribute to axle hop that can feel like shudder. Before attempting to duplicate this concern ask the customer if the condition occurs when the vehicle is loaded or has a trailer attached or if the vehicle is unloaded. This condition can also be caused by rear axle hop especially when backing a trailer up a hill. When attempting to duplicate the condition have another person watch the rear tires to verify a possible hop condition. Also when attempting to duplicate the condition allow one second after moving the shift lever to the reverse position before depressing the accelerator pedal. Increasing throttle before one second may result in slip or shudder even though there is not a problem with the transmission as the clutches are not fully filled and applied. If slip or shudder occurs verify that reverse boost can be obtained. Use a line pressure gauge to monitor line pressure and a Tech 2(R) to monitor PSC amperage during the concern and document in a TAC case. Engage D4 raise the engine RPM to 1000 and allow three seconds for line pressure to stabilize. Record the line pressure. Engage reverse raise engine the RPM to 1000 and allow three seconds for line pressure to stabilize and record line pressure again. Reverse pressure should be at least 20 psi (138 kPa) higher than drive pressure. Find an identical vehicle and duplicate the same driving maneuver. If it does exhibit the same symptom this may be an unreasonable driving maneuver and repairs may not be necessary. If another vehicle does not exhibit this concern the PCM should be reprogrammed. A revised transmission calibration has been developed to address these issues. Reprogram the PCM with updated calibration files using the TIS2WEB Service Programming System (SPS) application. As always make sure your Tech 2(R) is updated with the latest software version. Important: These calibrations will be "selectable" and should only be used to correct a customer concern as detailed above. Use of this calibration in a vehicle without these concerns may result in comments of harsh engagement into reverse. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-010 > Feb > 08 > Engine, A/T Controls - A/T Shudder/Slip in Reverse > Page 9156 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-06-04-063 > Oct > 05 > Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set > Page 9161 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-07-30-012 > May > 05 > Engine Controls - 4L60E/4L65E A/T, 2-3 Shift Clunk Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls 4L60E/4L65E A/T, 2-3 Shift Clunk Noise Bulletin No.: 05-07-30-012 Date: May 09, 2005 TECHNICAL Subject: 4L60-E/4L65-E Automatic Transmission 2-3 Shift Clunk (Reprogram Powertrain Control Module (PCM) Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005 GMC Sierra, Yukon with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission Condition Some customers may comment on a 2-3 shift clunk noise. Typically, this clunk noise is most noticeable when the 2-3 shift occurs under approximately 48 km/h (30 mph). Correction Important: ^ The PCM calibrations may REDUCE but not ELIMINATE the 2-3 shift clunk. ^ This bulletin only applies to the 2005 model year vehicles listed above. ^ As always, make sure your TECH 2(R) is updated with the latest software version. 1. To determine if this calibration will help to reduce 2-3 shift clunk, use the Tech 2 to navigate to the transmission diagnostic section and view the 2-3 shift adapt cells. ^ If the 2-3 adapt cell values are negative, this calibration change will have minimal benefit in reducing the 2-3 shift clunk. ^ If the 2-3 adapt cell values are above approximately + 5 psi, this calibration may provide a reduction in the 2-3 shift clunk. Important: These calibrations also contain the second gear start correction as detailed in bulletin 05-07-30-013. 2. Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 5 or later available May 1, 2005. Refer to Service Programming System (SPS) in Vehicle Control Systems in the appropriate SI Document. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-07-30-012 > May > 05 > Engine Controls - 4L60E/4L65E A/T, 2-3 Shift Clunk Noise > Page 9166 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-07-30-013 > May > 05 > Engine Controls - 4L60E/4L65E A/T 2nd Gear Start PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls 4L60E/4L65E A/T 2nd Gear Start Bulletin No.: 05-07-30-013 Date: May 09, 2005 TECHNICAL Subject: 4L60-E/4L65-E Automatic Transmission Second Gear Start, Lack/Loss of Power When Accelerating From a Stop (Reprogram Powertrain Control Module (PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2004-2005 GMC Savana, Sierra, Yukon 2004-2005 HUMMER H2 with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission Condition Some customers may comment on a slip on launch, low power on a launch or a second gear start when accelerating from a stop. This condition is usually very intermittent, occurring only once in a few thousand miles of driving. A Tech 2 or VDR snapshot of the event may show 2nd gear being commanded for approximately two seconds, then 1st gear commanded as would be expected. Cause This condition may be caused by an intermittent VSS signal, which causes the PCM to command second gear. Important: There are other conditions that can cause the transmission to start in a gear higher than first. The following are a few of these conditions. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. ^ Debris on top of the spacer plate or in the valve body or a leaking shift solenoid can cause a 4L60-E or 4L65-E transmission to start in a gear higher than first. A start in a higher gear caused by any of these conditions typically occurs with much greater frequency. Refer to Service Bulletin 01-07-30-036D or newer for diagnostic information of these conditions. ^ Placing the shift lever in the D2 position will cause a 4L60-E or 4L65-E transmission to start in second gear. Correction Important: ^ This bulletin ONLY applies to 2004-2005 models year vehicles listed above. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. 1. Using a scan tool, check for the presence of DTCs. If DTCs are present, refer to the appropriate SI Document before proceeding with this calibration. Important: These calibrations also contain the 2-3 shift clunk calibration as detailed in bulletin 05-07-30-012. 2. Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 5 or later available May 1, 2005. Refer to Service Programming System (SPS) in Vehicle Control Systems in the appropriate SI Document. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-07-30-013 > May > 05 > Engine Controls - 4L60E/4L65E A/T 2nd Gear Start > Page 9171 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign - ECM Software Upgrade Bulletin No.: 06535 Date: August 09, 2006 SYSTEM SOFTWARE UPGRADE Subject: 06535-ON-BOARD DIAGNOSTIC (OBD) SYSTEM SOFTWARE UPGRADE - OBD SYSTEM IMPROVEMENTS (REPROGRAM POWERTRAIN CONTROL MODULE {PCM}) Models: 2004-05 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2004-05 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2004-05 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 8.0 for 2006 or later, broadcast to dealers on August 6, 2006 or TIS 2 Web version 8.0 for 2006 (website version of TIS); and on TIS DVD version 8.0 / 2006 or later, mailed to dealers beginning August 23, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06535 remains 'open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or DVD availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Note: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic head lamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade > Page 9177 are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view Summary screen. 15. Verify that current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade > Page 9178 For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Pressure Regulating Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9186 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9187 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9188 Pressure Regulating Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9191 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 9192 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 9193 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Transmission Shift Lock Control Actuator Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 9197 Shift Interlock Solenoid: Description and Operation Automatic Transmission Shift Lock Control Description and Operation Automatic Transmission Shift Lock Control System The automatic transmission shift lock control is a safety device that prevents an inadvertent shift out of PARK when the ignition is ON. The driver must press the brake pedal before moving the shift lever out of the PARK position. The system consists of the following components: ^ The automatic transmission shift lock control solenoid. ^ The automatic transmission shift lock control switch. ^ The park/neutral position switch. With the ignition in the ON position, battery positive voltage is supplied to the park/neutral position switch. When the transmission is in the PARK position the contacts in the park/neutral position switch are closed. This allows current to flow through the switch to the automatic transmission shift lock control switch. The circuit continues through the normally-closed switch to the automatic transmission shift lock control solenoid. The automatic transmission shift lock control solenoid is permanently grounded. This energizes the automatic transmission shift lock control solenoid, locking the shift linkage in the PARK position. When the driver presses the brake pedal the contacts in the automatic transmission shift lock control switch open, causing the automatic transmission shift lock control solenoid to release. This allows the shift lever to move from the PARK position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 9198 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to Restraint Systems Caution in Service Precautions. Disable the Restraint system. Refer to Restraint Systems Disabling and Enabling Zone 3 in Restraint Systems. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 9199 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the Body Control Module. 6. Enable the Restraint systems. Refer to Restraint Systems Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 9204 Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Shift Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9207 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9208 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9209 Shift Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Shift Solenoid: Diagrams 4L60-E/4L65-E 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9212 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9213 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9214 Shift Solenoid: Diagrams 4L80-E/4L85-E 1-2 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9215 2-3 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 9216 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 9217 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 9218 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 9219 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Torque Converter Clutch Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9224 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9225 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9226 Torque Converter Clutch Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Torque Converter Clutch Solenoid: Diagrams 4L60-E/4L65-E Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9229 Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side (M30)/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9230 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9231 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector.Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9232 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9233 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9234 ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9235 ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 Transfer Case Actuator: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 9241 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 9242 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 9243 Transfer Case Actuator: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 9244 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 Transfer Case Actuator: Service and Repair NVG 246-NP8 Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield. 2. Remove the front propeller shaft. 3. Disconnect the transfer case switch electrical connector (2). 4. Disconnect the encoder motor electrical connector (7). 5. Remove the encoder motor bolts. 6. Remove the encoder motor. 7. Remove the actuator insulator gasket. 8. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the transfer case at the shift shaft, using a crescent wrench if necessary. ^ When installing the encoder motor, ensure that the encoder motor is indexed correctly and the motor is flat against the transfer case before tightening the bolts. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 9247 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector (7). 6. Connect the transfer case switch electrical connector (2). 7. Install the front propeller shaft. 8. Install the transfer case shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 9248 Transfer Case Actuator: Service and Repair NVG 263-NP1 Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 9249 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Pressure Regulating Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9256 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9257 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9258 Pressure Regulating Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9261 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 9262 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 9263 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Transmission Shift Lock Control Actuator Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 9267 Shift Interlock Solenoid: Description and Operation Automatic Transmission Shift Lock Control Description and Operation Automatic Transmission Shift Lock Control System The automatic transmission shift lock control is a safety device that prevents an inadvertent shift out of PARK when the ignition is ON. The driver must press the brake pedal before moving the shift lever out of the PARK position. The system consists of the following components: ^ The automatic transmission shift lock control solenoid. ^ The automatic transmission shift lock control switch. ^ The park/neutral position switch. With the ignition in the ON position, battery positive voltage is supplied to the park/neutral position switch. When the transmission is in the PARK position the contacts in the park/neutral position switch are closed. This allows current to flow through the switch to the automatic transmission shift lock control switch. The circuit continues through the normally-closed switch to the automatic transmission shift lock control solenoid. The automatic transmission shift lock control solenoid is permanently grounded. This energizes the automatic transmission shift lock control solenoid, locking the shift linkage in the PARK position. When the driver presses the brake pedal the contacts in the automatic transmission shift lock control switch open, causing the automatic transmission shift lock control solenoid to release. This allows the shift lever to move from the PARK position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 9268 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to Restraint Systems Caution in Service Precautions. Disable the Restraint system. Refer to Restraint Systems Disabling and Enabling Zone 3 in Restraint Systems. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 9269 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the Body Control Module. 6. Enable the Restraint systems. Refer to Restraint Systems Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 9274 Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Shift Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9277 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9278 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9279 Shift Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Shift Solenoid: Diagrams 4L60-E/4L65-E 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9282 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9283 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9284 Shift Solenoid: Diagrams 4L80-E/4L85-E 1-2 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9285 2-3 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 9286 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 9287 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 9288 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 9289 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Torque Converter Clutch Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9294 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9295 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9296 Torque Converter Clutch Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Torque Converter Clutch Solenoid: Diagrams 4L60-E/4L65-E Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9299 Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side (M30)/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9300 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9301 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector.Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9302 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9303 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9304 ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9305 ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Accumulator: Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 9310 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 9311 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 9312 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Accumulator: Service and Repair 4L60-E/4L65-E Accumulator Assembly, Spacer Plate, and Gaskets ^ Tools Required J 25025-B Pump and Valve Body Alignment Pin Set - J 36850 Transjel Lubricant Removal Procedure 1. Remove the transmission filter. 2. Important: The 1-2 accumulator can be removed without removing the valve body. Remove the valve body. 3. Remove the accumulator cover bolts. 4. Remove the 1-2 accumulator cover. 5. Important: regular production option (RPO) M33 transmissions do not use a 1-2 accumulator spring inner (104). Remove the 1-2 accumulator cover (57) and pin. 6. Disassemble the 1-2 accumulator assembly (54, 56, 57, 104). 7. Inspect the 1-2 accumulator springs for cracks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9315 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 11. Remove the spacer plate support bolts. 12. Important: Use care not to drop the following items that will be removed along with the spacer plate: ^ The number 1 checkball ^ The 3-4 accumulator spring ^ The 3-4 accumulator pin Remove the spacer plate support. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9316 13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. 14. Remove the 3-4 accumulator piston (2). 15. Inspect the 3-4 accumulator spring for cracks. 16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. 17. Inspect the 3-4 accumulator piston for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9317 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case.Ensure that the 3-4 accumulator piston legs face away from the transmission case. 4. Install the J 25025-B (2, 3) to the transmission case. 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. ^ The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. ^ The valve body gasket is identified by a V.Be sure to place the valve body gasket on the valve body side of the spacer plate. 6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9318 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the spacer plate support and the spacer plate support bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9319 13. Important: RPO M33 transmissions do not use a 1-2 accumulator spring inner (104). Assemble the 1-2 accumulator assembly (54, 56, 57, 104). Ensure that the piston legs face the accumulator cover. 14. Install the 1-2 accumulator cover (57) and pin. 15. Install the 1-2 accumulator cover and the accumulator cover bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 16. Remove the J 25025-B from the transmission case. 17. Install the valve body. 18. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9320 Accumulator: Service and Repair 4L80-E/4L85-E Accumulator Housing Replacement ^ Tools Required J 25025-5 Valve Body Align Pin Removal Procedure 1. Remove the valve body. 2. Remove the 3rd and 4th clutch accumulator housing bolts (1). 3. Remove the 3rd and 4th clutch accumulator housing (8). 4. Remove the accumulator housing gasket (6). The accumulator housing gasket may be stuck to the spacer plate (5). 5. Remove the 3rd clutch accumulator piston spring (7). 6. Remove the 4th clutch accumulator piston spring (2). 7. Remove the valve body spacer plate (5). 8. Remove the valve body to spacer plate gasket (4) from the spacer plate (5). Third and Fourth Clutch Accumulator Disassembly 1. Important: Apply low pressure compressed air to the hole at the top of the accumulator housing to assist with the piston removal. Remove the 3rd clutch accumulator piston (2). 2. Remove the 3rd clutch accumulator piston seals (1, 3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9321 3. Remove the 4th clutch accumulator piston pin retainer ring (5). 4. Remove the 4th clutch accumulator piston (4) and pin (2) from the accumulator housing (1). 5. Remove the 4th clutch accumulator piston pin (2) from the accumulator housing (1). 6. Remove the 4th clutch accumulator piston seal (3) from the accumulator housing (1). Third and Fourth Clutch Accumulator Assembly 1. Install the 3rd clutch accumulator piston inner (3) and outer (1) seals. Lubricate the 3rd clutch accumulator piston seals (1, 3) with DEXRON(R) III automatic transmission fluid. 2. Install the 3rd clutch accumulator piston (2). 3. Install the 4th clutch accumulator piston seal (3). Lubricate the 4th clutch accumulator piston seal (3) with DEXRON(R) III automatic transmission fluid. 4. Assemble the 4th clutch accumulator piston pin (2) with the 4th clutch accumulator piston (4). 5. Install the 4th clutch accumulator piston assembly into the accumulator housing (1). 6. Install the 4th clutch accumulator piston pin retainer ring (5) onto the 4th clutch accumulator piston pin (2). Installation Procedure 1. Install J 25025 into the valve body bolt hole where the manual shaft detent roller and spring is mounted. 2. Install the valve body gasket (2) onto the accumulator housing (1). 3. Install the valve body spacer plate (3) onto the valve body gasket (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9322 4. Install the third and fourth clutch accumulator housing gasket (3). 5. Install the third clutch accumulator piston spring (1). This spring is the longer of the two springs. 6. Install the fourth clutch accumulator piston spring (4). 7. Install the third and fourth clutch accumulator housing assembly (5) onto the control valve body assembly (2). 8. Install the six accumulator housing bolts (6). Start the bolts finger tight and work towards the opposite end. 9. Notice: Refer to Fastener Notice in Service Precautions. Tighten the accumulator housing bolts sequentially. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 10. Remove the J 25025. 11. Install the valve body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Band Apply Servo: Service and Repair 4L60-E/4L65-E 2-4 Servo ^ Tools Required J 29714-A Servo Cover Depressor Removal Procedure 1. Remove the exhaust pipe. 2. Remove the heat shield bolts. 3. Remove the heat shield. 4. Remove the oil pan bolt below the servo. 5. Install the J 29714-A . 6. Tighten the bolt on J 29714-A in order to compress the servo cover. 7. Remove the servo cover ring. 8. Remove the J 29714-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9327 9. Remove the servo cover and O-ring seal. If the cover is hung up on the seal, use a pick (2) in order to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 10. Remove the 2-4 servo. 11. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects: ^ Cracks ^ Scoring ^ Burrs and nicks Installation Procedure 1. Install NEW seals onto the servo pistons and the servo cover. 2. Install the 2-4 servo. 3. Install the J 29714-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9328 4. Tighten the bolt on J 29714-A in order to compress the servo cover. 5. Install the servo cover ring. 6. Remove the J 29714-A . 7. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolt. ^ Tighten the bolt to 11 Nm (97 inch lbs.). 8. Install the heat shield and bolts. ^ Tighten the bolts to 17 Nm (13 ft. lbs.). 9. Install the exhaust pipe. 10. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9329 Band Apply Servo: Service and Repair 4L80-E/4L85-E Reverse Servo Replacement Reverse Servo Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the rear servo from the transmission case in the following order: 1. Cover bolts (6) 2. Cover (5) 3. Cover gasket (4) 4. Bottom retaining clip (3) 5. Servo piston (2) 6. Outer ring oil seal (1) 7. Inner ring oil seal (7) 8. Accumulator piston (8) 9. Piston seal (9) 10. Washer (10) 11. Servo spring (11) 12. Servo spring retainer (12) 13. Selective pin (13) 14. Accumulator spring (14) Installation Procedure 1. Install the rear servo to the transmission in the following order: 1. Accumulator spring (14) 2. Selective pin (13) 3. Servo spring retainer (12) 4. Servo spring (11) 5. Washer (10) 6. Piston seal (9) 7. Accumulator piston (8) 8. Inner ring oil seal (7) 9. Outer ring oil seal (1) 10. Servo piston (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9330 11. Bottom retaining clip (3) 12. Cover gasket (4) 13. Cover (5) 14. Cover bolts (6) Notice: Refer to Fastener Notice in Service Precautions. 2. Tighten the cover bolts (61). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Install the transmission filter. Forward Servo Replacement Forward Servo Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the forward servo cover bolts, cover, and gasket. 3. Remove the following parts: 1. Forward servo piston pin (5) 2. O-ring seal (4) 3. Servo piston (3) 4. Retainer (2) 6. Piston spring (1) Installation Procedure 1. Install the following parts: ^ Piston spring (1) ^ Retainer (2) ^ Servo piston (3) ^ O-ring seal (4) ^ Forward servo piston pin (5) Notice: Refer to Fastener Notice in Service Precautions. 2. Install the forward servo gasket, cover, and bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Automatic Transmission Shift Lock Control Component Views Lower Steering Column Components Lower Steering Column Components 1 - A/T Shift Lock Control Actuator 2 - Steering Column Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis Case: Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 9338 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 9347 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 9357 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 9371 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 9372 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear > Page 9382 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear > Page 9383 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-009B > May > 08 > A/T 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-015 > Mar > 08 > A/T MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift Clutch: All Technical Service Bulletins A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift INFORMATION Bulletin No.: 08-07-30-015 Date: March 27, 2008 Subject: Diagnostic Information on MN8, MT1 SES/MIL Illuminated, DTC P0757, Harsh Shift, Delayed 2-3 Shift, 2-3 Shift Flare, No Third Gear, Slips in Third Gear or Reverse Models: 2002-2007 Chevrolet Avalanche 2500 Series, Silverado Classic, Suburban 2500 Series 2002-2008 Chevrolet Express 2002-2007 GMC Sierra Classic, Yukon XL 2500 Series 2002-2008 GMC Savana with HYDRA‐MATIC(R)4L80‐E (RPO MT1) or4L85‐E (RPO MN8) Automatic Transmission The purpose of this bulletin is to provide technicians with additional diagnostic information on DTC P0757. Refer to Service Information (SI) for DTC P0757, 2-3 Shift Solenoid Valve Performance No Third or Fourth Gear. Additional 4L80‐E or 4L85‐E transmission symptoms may be a harsh shift, delayed 2-3 shift, no third gear or slip in third or reverse, or a 2-3 shift flare. The transmission fluid inspection may or may not indicate distressed clutches. On all 2002-2006 vehicles and certain 2007-2008 vehicles, check for any debris caught in the # 11 check ball. If debris is found, repair per Service Bulletin 08-07-30-001. Also inspect the direct clutch for damage that may have been caused by a leak in the oil circuit that may be a result of the debris. If no debris is found, and no other cause is found when referring to Service Information (SI) for DTC P0757, valve body replacement may be indicated. Also check the 2-3 shift valve for debris or leakage. If none of these items seem to have a concern, replace the 2-3 shift solenoid due to a possible sticking pintle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 9397 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 9398 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only Blower Motor Resistor: All Technical Service Bulletins A/C - Blower Motor Inop. or Works On Low Speed Only Bulletin No.: 05-01-38-012C Date: November 02, 2006 TECHNICAL Subject: EI05082 - Loss of Blower Motor Speeds Except for Low Speed or Inoperative (Replace Blower Motor Resistor and Resistor Module Connector) Models: 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2007 Chevrolet Silverado (Classic) Built Prior to September 1, 2006 2004-2006 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL 2007 GMC Sierra (Classic) Built Prior to September 1, 2006 with HVAC System AC Front, Manual Temp Control (RPO CJ3) or Heater Only (RPO C42) Supercede: This bulletin is being revised to clarify the Warranty Information. Please discard Corporate Bulletin Number 05-01-38-012B (Section 01 - HVAC). Condition Some customers may comment that the blower will only work on low speeds or has become inoperative. Correction REPLACE THE BLOWER MOTOR RESISTOR AND RESISTOR MODULE CONNECTOR. Replace the blower motor resistor and module connector using the following procedure: Remove the blower fuse. Fullsize Trucks and Utility Vehicles - Htr A/C & HVAC 1 fuses Midsize Utility Vehicles - Blower Fuse 35 located in the Underhood Fuse Block Lower the hush panel or close-out panel enough to gain access to the resistor module connector. Disconnect the connector from the resistor module. Remove the tape from the wiring harness to expose the wiring. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only > Page 9403 Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Tip Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Install the new connector. Use the yellow splice sleeves provided with the connector. Install new blower motor resistor. Reinstall the fuse or connector block. Test the blower motor to make sure all speeds are functional. Reinstall the hush panel/close-out panel. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only > Page 9404 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 9410 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 9411 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only > Page 9416 Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Tip Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Install the new connector. Use the yellow splice sleeves provided with the connector. Install new blower motor resistor. Reinstall the fuse or connector block. Test the blower motor to make sure all speeds are functional. Reinstall the hush panel/close-out panel. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only > Page 9417 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls - Shared Diagnostic Trouble Codes Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Extension Housing: Service and Repair 4L60-E/4L65-E Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O-ring seal (3). Installation Procedure 1. Install a new case extension O-ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (1). ^ Tighten the bolts (1) to 45 Nm (33 ft. lbs.). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9426 Extension Housing: Service and Repair 4L80-E/4L85-E Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission support and the transmission mount. 6. Remove the case extension bolts (3). 7. Remove the case extension (1). 8. Remove and discard the case extension O-ring seal (2). Installation Procedure 1. Install a new case extension O-ring seal (2). 2. Install the case extension (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (3). ^ Tighten the bolts (3) to 34 Nm (25 ft. lbs.). 4. Install the transmission support and the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with Dexron(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 9431 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 9432 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 9433 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4L60-E Pan Removal ........................................................................................... .......................................................................................................... 4.7L (5.0 Qt) Overhaul .............. .............................................................................................................................................................. ............................ 10.6L (11.0 Qt) 4L80-E Overhaul ........................................................................... ............................................................................................................................. 12.8L (13.5 Qt) Pan Removal .............................................................................................................................................. ....................................................... 7.3L (7.7 Qt) Allison Overhaul ..................................................... ................................................................................................................................................... 12.0L (12.7 Qt) Fluid and Filter Change ........................................................................................................ ............................................................................. 7.0L (7.4 Qt) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 9436 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 4L60-E/4L65-E Transmission Fluid Checking Procedure Fluid - A/T: Testing and Inspection 4L60-E/4L65-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 4L60-E/4L65-E Transmission Fluid Checking Procedure > Page 9439 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82-93°C (180-200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about 3 seconds in each range, ending in PARK. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 4L60-E/4L65-E Transmission Fluid Checking Procedure > Page 9440 Fluid - A/T: Testing and Inspection 4L80-E/4L85-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 4L60-E/4L65-E Transmission Fluid Checking Procedure > Page 9441 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82-93°C (180-200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about three seconds in each range, ending in Park. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E Fluid - A/T: Service and Repair 4L60-E/4L65-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9444 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9445 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82-93°C (180-200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about 3 seconds in each range, ending in PARK. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9446 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9447 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. 4. Install the oil pan and NEW gasket. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Refer to Transmission Fluid Checking Procedure and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9448 Fluid - A/T: Service and Repair 4L80-E/4L85-E Transmission Fluid Checking Procedure Transmission Fluid Checking Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9449 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9450 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 82-93°C (180-200°F). 2. Park the vehicle on a level surface. 3. With your foot on the brake, move the shift lever through each gear range. Pause for about three seconds in each range, ending in Park. 4. Apply the parking brake and let the engine idle for 3 minutes. 5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close. 6. Wait 3 seconds and remove the indicator. 7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading. Automatic Transmission Fluid/Filter Replacement Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9451 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9452 Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9453 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9454 Fluid - A/T: Service and Repair Fluid Checking Procedure FLUID CHECKING PROCEDURE WITHOUT ALLISON TRANSMISSION WHEN TO CHECK AND CHANGE A good time to check the automatic transaxle fluid level is when the engine oil is changed. Change the fluid and filter at the intervals listed in the Maintenance schedule, and be sure to use the proper transaxle fluid. HOW TO CHECK Because this operation can be a little difficult, you may choose to have this done at the dealership service department. If you do it yourself, be sure to follow all the instructions here, or you could get a false reading on the dipstick. NOTICE: Too much or too little fluid can damage the transaxle. Too much can mean that some of the fluid could come out and fall on hot engine or exhaust system parts, starting a fire. Too little fluid could cause the transaxle to overheat. Be sure to get an accurate reading if you check the transaxle fluid. Wait at least 30 minutes before checking the transaxle fluid level if you have been driving: ^ When outside temperatures are above 90°F (32°C). ^ At high speed for quite a while. ^ In heavy traffic - especially in hot weather. ^ While pulling a trailer. To get the right reading, the fluid should be at normal operating temperature, which is 180°F to 200°F (82°C to 93°C). Get the vehicle warmed up by driving about 15 miles (24 km) when outside temperatures are above 50°F (10°C). If it is colder than 50°F (10°C), you may have to drive longer. CHECKING THE FLUID LEVEL Prepare the vehicle as follows: 1. Park the vehicle on a level place. Keep the engine running. 2. With the parking brake applied, place the shift lever in PARK (P). 3. With your foot on the brake pedal, move the shift lever through each gear, pausing for about three seconds in each gear. Then, position the shift lever in PARK (P). 4. Let the engine run at idle for three to five minutes. 5. Then, without shutting off the engine, follow these steps: ^ The automatic transaxle fluid dipstick handle is the black loop located toward the rear of the engine. ^ Pull out the dipstick and wipe it with a clean rag or paper towel. ^ Push it back in all the way, wait three seconds, and pull it back out again. ^ Check both sides of the dipstick, and read the lower level. The fluid level must be in the crosshatched area. ^ If the fluid level is in the acceptable range, push the dipstick back in all the way. CONSISTENCY OF READINGS Always check the fluid level at least twice using the procedure described previously. Consistency (repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist, check the transmission breather hose to be sure it is clean and unclogged. HOW TO ADD FLUID If the fluid level is low, add only enough of the proper fluid to bring the level into the crosshatched area on the dipstick. 1. Pull out the dipstick. 2. Using a long-neck funnel, add enough fluid at the dipstick hole to bring it to the proper level. It does not take much fluid, generally less than one pint (0.5 liters). Do not overfill. NOTICE: Use of automatic transaxle fluid labeled other than DEXRON-III may damage your vehicle, and the damages may not be covered by your warranty. Always use DEXRON-III labeled automatic transaxle fluid. 3. After adding fluid, recheck the fluid level as described under "How to Check," earlier in this article. When the correct fluid level is obtained, push the dipstick back in all the way. WITH ALLISON TRANSMISSION NOTE: Be sure to follow all the instructions here, or you could get a false reading on the dipstick. NOTICE: Too much or too little fluid can damage your transmission. Too much can mean that some of the fluid could come out and fall on hot Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9455 engine part or exhaust system parts, starting a fire. Too little fluid could cause the transmission to overheat. Be sure to get an accurate reading if you check your transmission fluid. Wait at least 30 minutes before checking the transmission fluid level if you have been driving: * When outside temperatures are above 90°F (32°C). * At high speed for quite a while. * In heavy traffic -- especially in hot weather. * While pulling a trailer. CHECKING THE FLUID LEVEL Prepare your vehicle as follows: 1. Park your vehicle on a level place. Keep the engine running. 2. With the parking brake applied, place the shift lever in PARK (P). 3. With your foot on the brake pedal, run the engine for at least once minute and shift to DRIVE (D). Then shift to NEUTRAL (N) and then REVERSE (R) to fill the hydraulic system. Then, position the shift lever in PARK (P). 4. Allow the engine to run at idle (500-800 rpm). Slowly release the brake pedal. 5. Then, without shutting off the engine, follow these steps: COLD CHECK PROCEDURE The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made. The fluid level rises as fluid temperature increases. Do not fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures. 1. Pull out the dipstick and wipe it with a clean rag or paper towel. 2. Push it back in all the way, wait three seconds and then pull it back out again. 3. Check the fluid level reading. Repeat the check procedure to verify the reading. 4. If the fluid level is within the COLD CHECK band, the transmission may be operated until the fluid is hot enough to perform a hot check. If the fluid level is not within the COLD CHECK band, add or drain fluid as necessary to bring the level into the middle of the COLD CHECK band. 5. Perform a hot check at the first opportunity after the normal operating temperature of 160°F (71°C) to 200°F (93°C) is reached. 6. If the fluid level is in the acceptable range, push the dipstick back in all the way. HOT CHECK PROCEDURE The fluid must be hot to ensure an accurate check. The fluid level rises as the temperature increases. 1. Operate the transmission in DRIVE (D) range until the normal operating temperature of 160°F (71°C) to 200°F (93°C) is reached. 2. Pull out the dipstick and wipe it with a clean rag or paper towel. 3. Push it back in all the way, wait three seconds and then pull it back out again. Repeat the check procedure to verify the reading. 4. Safe operating level is within the HOT RUN band on the dipstick. The width of the HOT RUN band represents approximately 1.06 quart (1.0 liter) of fluid at normal operating temperature. 5. If the fluid level is not within the HOT RUN band, add or drain fluid as necessary to bring the fluid level to within the HOT RUN band. 6. If the fluid level is in the acceptable range, push the dipstick back in all the way. CONSISTENCY OF READINGS Always check the fluid level at least twice using the procedures described previously. Consistency (repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist, check the transmission breather to be sure it is clean and unclogged. If readings are still inconsistent, contact your dealer. HOW TO ADD AUTOMATIC TRANSMISSION FLUID Refer to the Maintenance Schedule to determine what kind of transmission fluid to use. Add fluid only after checking the transmission fluid while it is hot. A cold check is used only as a reference. If the fluid level is low, add only enough of the proper fluid to bring the level up to the HOT area for a hot check. It does not take much fluid, generally less than one pint (0.5 liters). Do not overfill. NOTICE: Use of the incorrect automatic transmission fluid may damage your vehicle, and the damages may not be covered by your warranty. Always use the automatic transmission fluid. After adding fluid, recheck the fluid level as described under "How to Check Automatic Transmission Fluid," earlier in this section. When the correct fluid level is obtained, push the dipstick back in all the way. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E Fluid Filter - A/T: Service and Repair 4L60-E/4L65-E Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. 9. Remove the oil pan and the gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9460 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9461 4. Install the oil pan and NEW gasket. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Refer to Transmission Fluid Checking Procedure and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9462 Fluid Filter - A/T: Service and Repair 4L80-E/4L85-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9463 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9464 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9465 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 9470 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 9471 Fluid Line/Hose: Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 9472 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Fluid Line/Hose: Service and Repair 4L60-E/4L65-E Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the front grille. 2. Disconnect the auxiliary transmission fluid cooler lines from the auxiliary oil cooler. Refer to Transmission Fluid Cooler Line Quick Connect Fitting. 3. Disconnect the transmission fluid cooler lines from the radiator. Refer to Transmission Fluid Cooler Line Quick Connect Fitting. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the engine protection shield. 6. Disconnect the oil cooler lines from the transmission. Refer to Transmission Fluid Cooler Line Quick Connect Fitting. 7. Remove the oil cooler lines from the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9475 Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Connect the cooling lines to the transmission. Refer to Transmission Fluid Cooler Line Quick Connect Fitting. 3. Install the engine protection shield. 4. Lower the vehicle. 5. Connect the transmission fluid cooler lines from the radiator. Refer to Transmission Fluid Cooler Line Quick Connect Fitting. 6. Connect the transmission fluid cooler hose to the Auxiliary oil cooler. Refer to Transmission Fluid Cooler Line Quick Connect Fitting. 7. Install the front grille. Transmission Fluid Cooler Line Quick Connect Fitting Transmission Fluid Cooler Line Quick Connect Fitting Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9476 1. Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 inch). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure 1. Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Install a new retaining ring into the quick connect fitting using the following procedure: 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9477 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9478 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 10. Important: Do not manually depress the retaining clip when installing the plastic cap. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9479 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9480 Fluid Line/Hose: Service and Repair 4L80-E/4L85-E Transmission Fluid Cooler Line Quick Connect Fitting Transmission Fluid Cooler Line Quick Connect Fitting Removal Procedure 1. Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 inch). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure 1. Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Install a new retaining ring into the quick connect fitting using the following procedure: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9481 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9482 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 10. Important: Do not manually depress the retaining clip when installing the plastic cap. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9483 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the grille assembly. 2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. 3. Remove the transmission fluid cooler hose from the radiator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9484 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the engine protection shield. 6. Remove the transmission fluid cooler hoses from the transmission. 7. Remove the transmission fluid cooler hoses from the retainer on the engine. 8. Remove the transmission fluid cooler hoses from the vehicle. Installation Procedure 1. Install the transmission fluid cooler hoses to the vehicle. 2. Install the transmission fluid cooler hoses to the transmission. 3. Install the transmission fluid cooler hoses to the retainer on the engine. 4. Install the engine protection shield. 5. Lower the vehicle. 6. Install the transmission fluid cooler hose to the radiator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9485 7. Install the transmission fluid cooler hose from the Auxiliary oil cooler. 8. Install the grille assembly. Vent Hose Vent Hose Removal Procedure 1. Remove the vent hose clip. 2. Remove the vent hose from the transmission vent. Installation Procedure 1. Install the vent hose to the transmission. 2. Install the vent hose to the clip. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt and the clamp. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade Fluid Pan: Technical Service Bulletins A/T - Fluid Pan Magnet Upgrade INFORMATION Bulletin No.: 08-07-30-040B Date: May 05, 2009 Subject: Information on Normal Maintenance or Warranty Service for 4T40, 4T45, 4T65, 4L60 Automatic Transmission Oil Pan Magnet Upgrade Models: 2002-2009 GM Passenger Cars and Light Duty Trucks Equipped With the Following Transmissions: 4T40-E or 4T45 HYDRA-MATIC(R) Automatic Transmission (RPOs MN4, MN5, ME7) 4T65 Transmission (RPO M15 and MN7) 4L60 Transmission and Derivatives (RPO M30 is 4L60, M32 is 4L65, M70 is 4L70) Attention: Do not remove the transmission oil pan unless normal maintenance or diagnosis of a customer concern requires it. .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add 4T65 and 4L60 transmissions. Please discard Corporate Bulletin Number 08-07-30-040A (Section 07 - Transmission/Transaxle). .............................................................................................................................................................. .................................................................................. A new transmission oil pan magnet, P/N 29535617, was released for service. The current square transmission oil pan magnet may become saturated with normal ferrous sediment and the Pressure Control Solenoid (PCS) is now collecting ferrous sediment, making it vary from design. For a given current the PCS electromagnet is stronger, causing the line pressure to be less than needed. When checking PCS line pressure (refer to Line Pressure Check in SI) and it shows that the line pressure is lower than required (refer to Current-Amps/Line Pressure Chart in SI), for a given current at the PCS or the transmission oil pan was removed (for either normal maintenance or warranty service), only then should the transmission oil pan magnet be upgraded. 1. Remove and discard the original square transmission oil pan magnet and install a new one in the current location (See graphics below for the correct application). 2. Install the second new transmission oil pan magnet in the following location as shown in the illustration. 4T40 & 4T45 4T65E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 9490 Note Only on 4T65E, the second magnet (left) should be attached to the transmission filter. If the magnet is attached in any other location, it may cause interference (refer to graphic above). 4L60 Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 9491 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 4L60-E/4L65-E Fluid Pan: Specifications 4L60-E/4L65-E Oil Pan to Transmission Case Bolt ........................................................................................................................................................ 11 Nm (97 inch lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 9494 Fluid Pan: Specifications 4L80-E/4L85-E Oil Pan Drain Plug ............................................................................................................................... ..................................................... 34 Nm (25 ft. lbs.) Oil Pan to Case ................................................ ......................................................................................................................................... 24 Nm (18 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 9499 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Fluid Pressure Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9502 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9503 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9504 Fluid Pressure Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9507 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9508 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9509 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9510 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Remove the remaining valve body bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9511 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9512 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Notice: Refer to Fastener Notice in Service Precautions. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9513 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9514 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Do not install the transmission fluid indicator stop bracket and bolt at this time.Install but do not tighten the valve body bolts which retain only the valve body directly.Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9515 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9516 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9517 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Valve and Spring Replacement Fluid Pump: Service and Repair Torque Converter Clutch (TCC) Valve and Spring Replacement Torque Converter Clutch (TCC) Valve and Spring Replacement Removal Procedure 1. Remove the transmission filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the valve bore plug retainer ring (1). 3. Remove the following parts: ^ The valve bore plug ^ The TCC valve ^ The TCC valve spring Installation Procedure 1. Install the following parts: ^ The TCC valve spring ^ The TCC valve ^ The valve bore plug Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Valve and Spring Replacement > Page 9522 2. Install the valve bore plug retainer ring (1). 3. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Valve and Spring Replacement > Page 9523 Fluid Pump: Service and Repair Pressure Regulator Replacement Pressure Regulator Replacement ^ Tools Required J 36850 Transjel(R) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Valve and Spring Replacement > Page 9524 ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation SHIFT INDICATOR The instrument panel cluster (IPC) illuminates the shift indicator when the powertrain control module (PCM) determines that the vehicle should be shifted to the next higher gear. The IPC receives a class 2 message from the PCM requesting illumination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair Parking Pawl: Service and Repair Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite(R) or equivalent. 4. Install the retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 9536 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Pressure Regulating Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9541 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9542 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9543 Pressure Regulating Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9546 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 9547 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 9548 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls - Shared Diagnostic Trouble Codes Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 9562 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 9568 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 9569 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 9570 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 9571 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E Seals and Gaskets: Service and Repair 4L60-E/4L65-E Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. Unlock the transmission oil level indicator. 2. Remove the transmission oil level indicator. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Support the transmission using a suitable jack. 5. Remove the transmission mount nut. 6. Remove the transmission crossmember bolts/nuts. 7. Remove the transmission crossmember. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9574 8. Loosen the left exhaust pipe nuts. 9. Loosen the right exhaust pipe nuts. 10. Remove the insulator nuts and insulator from the bracket. 11. Remove the exhaust pipe hanger bracket bolts and bracket. 12. Lower the transmission slightly. 13. Disconnect the transmission oil cooler lines. Refer to Transmission Fluid Cooler Line Quick Connect Fitting . 14. Plug the transmission oil cooler line fittings. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9575 15. Remove the indicator tube nut. 16. Remove the indicator tube bolt, if equipped with RPO HP2. 17. Remove the oil level indicator tube. 18. Remove the seal from the transmission, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9576 19. Remove the oil level indicator tube, if equipped with RPO HP2. 20. Remove the seal from the transmission, if necessary. Installation Procedure 1. Install a NEW seal to the indicator tube. 2. Install the oil level indicator tube, if equipped with RPO HP2. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9577 3. Install a NEW seal to the indicator tube. 4. Install the oil level indicator tube. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the indicator tube bolt, if equipped with RPO HP2. ^ Tighten the bolt to 18 Nm (13 ft. lbs.). 6. Install the indicator tube nut. ^ Tighten the nut to 18 Nm (13 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9578 7. Remove the plugs from the transmission oil cooler line fittings. 8. Connect the transmission oil cooler lines. Refer to Transmission Fluid Cooler Line Quick Connect Fitting . 9. Install the exhaust pipe hanger bracket and bolts. ^ Tighten the bolts to 17 Nm (12 ft. lbs.). 10. Install the insulator and nuts to the bracket. ^ Tighten the nuts to 17 Nm (12 ft. lbs.). 11. Tighten the right exhaust pipe nuts. ^ Tighten the nuts to 50 Nm (37 ft. lbs.). 12. Tighten the left exhaust pipe nuts. ^ Tighten the nuts to 50 Nm (37 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9579 13. Install the transmission crossmember. 14. Install the transmission crossmember bolts/nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 15. Install the transmission mount nut. ^ Tighten the nut to 50 Nm (37 ft. lbs.). 16. Remove the support from the transmission. 17. Lower the vehicle. 18. Install the transmission oil level indicator. 19. Lock the transmission oil level indicator. Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9580 1. Remove the park/neutral position (PNP) switch. 2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to ensure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the bore until it is seated at the bottom of the bore. 4. Install the PNP switch. 5. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Accumulator Assembly, Spacer Plate, and Gaskets Accumulator Assembly, Spacer Plate, and Gaskets ^ Tools Required J 25025-B Pump and Valve Body Alignment Pin Set - J 36850 Transjel Lubricant Removal Procedure 1. Remove the transmission filter. 2. Important: The 1-2 accumulator can be removed without removing the valve body. Remove the valve body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9581 3. Remove the accumulator cover bolts. 4. Remove the 1-2 accumulator cover. 5. Important: regular production option (RPO) M33 transmissions do not use a 1-2 accumulator spring inner (104). Remove the 1-2 accumulator cover (57) and pin. 6. Disassemble the 1-2 accumulator assembly (54, 56, 57, 104). 7. Inspect the 1-2 accumulator springs for cracks. 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following conditions: ^ Porosity ^ Cracks ^ Scoring Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9582 ^ Nicks and scratches 11. Remove the spacer plate support bolts. 12. Important: Use care not to drop the following items that will be removed along with the spacer plate: ^ The number 1 checkball ^ The 3-4 accumulator spring ^ The 3-4 accumulator pin Remove the spacer plate support. 13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. 14. Remove the 3-4 accumulator piston (2). 15. Inspect the 3-4 accumulator spring for cracks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9583 16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. 17. Inspect the 3-4 accumulator piston for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches Installation Procedure 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case.Ensure that the 3-4 accumulator piston legs face away from the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9584 transmission case. 4. Install the J 25025-B (2, 3) to the transmission case. 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. ^ The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. ^ The valve body gasket is identified by a V.Be sure to place the valve body gasket on the valve body side of the spacer plate. 6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the spacer plate support and the spacer plate support bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9585 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. 13. Important: RPO M33 transmissions do not use a 1-2 accumulator spring inner (104). Assemble the 1-2 accumulator assembly (54, 56, 57, 104). Ensure that the piston legs face the accumulator cover. 14. Install the 1-2 accumulator cover (57) and pin. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9586 15. Install the 1-2 accumulator cover and the accumulator cover bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 16. Remove the J 25025-B from the transmission case. 17. Install the valve body. 18. Install the transmission filter. Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 21426 Extension Housing Seal Installer - J 36850 Transjel Lubricant Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Refer to Transmission Extension Housing Assembly Replacement. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9587 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9588 Seals and Gaskets: Service and Repair 4L80-E/4L85-E Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. Remove the oil level indicator. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the fill tube bracket nut. 4. Place a drain pan under the transmission. 5. Remove the fill tube. 6. Remove the transmission fill tube seal. Installation Procedure 1. Install the transmission fill tube seal. 2. Install the fill tube. 3. Remove the drain pan from under the transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9589 4. Install the fill tube bracket nut. 5. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil level indicator. ^ Tighten the nut to 47 Nm (35 ft. lbs.). 7. Fill the transmission to the proper level with Dexron(R) III transmission fluid. Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Remove the park/neutral position (PNP) switch. 2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the J 43911 so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9590 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Using J 43909 , remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP switch. 5. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 41505 Output Shaft Seal Installer - J 6125-1BSlide Hammer - J 23129 Universal Seal Remover - J 36850 Transmission Assembly Lubricant Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Using the J 6125-1B (1) and the J 23129 (2), remove the output shaft seal (3) from the extension housing (4). 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Refer to Transmission Extension Housing Assembly Replacement. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E > Page 9591 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 41505 (1) with a soft faced mallet to install the seal (2). 3. Install the seal (2) to the extension housing (3). 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with Dexron(R) III transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Automatic Transmission Shift Lock Control Component Views Lower Steering Column Components Lower Steering Column Components 1 - A/T Shift Lock Control Actuator 2 - Steering Column Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 9600 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Fluid Pressure Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9603 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9604 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9605 Fluid Pressure Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9608 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9609 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9610 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9611 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Remove the remaining valve body bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9612 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9613 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Notice: Refer to Fastener Notice in Service Precautions. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9614 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9615 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Do not install the transmission fluid indicator stop bracket and bolt at this time.Install but do not tighten the valve body bolts which retain only the valve body directly.Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9616 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9617 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 9618 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E > Page 9623 Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 9626 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 9627 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 9628 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9633 Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 9636 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9639 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9640 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9641 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9642 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9643 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Speed Sensor: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9648 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9649 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9650 Transmission Speed Sensor: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E Transmission Speed Sensor: Diagrams 4L80-E/4L85-E Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 9653 Automatic Transmission Output Shaft Speed (AT OSS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 9654 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Speed Sensor: Service and Repair 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9657 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9658 Transmission Speed Sensor: Service and Repair 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9659 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9660 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9661 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E > Page 9666 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Temperature Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9669 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9670 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9671 Transmission Temperature Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9672 Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams Transmission Shift Lock Control Actuator Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 9677 Shift Interlock Solenoid: Description and Operation Automatic Transmission Shift Lock Control Description and Operation Automatic Transmission Shift Lock Control System The automatic transmission shift lock control is a safety device that prevents an inadvertent shift out of PARK when the ignition is ON. The driver must press the brake pedal before moving the shift lever out of the PARK position. The system consists of the following components: ^ The automatic transmission shift lock control solenoid. ^ The automatic transmission shift lock control switch. ^ The park/neutral position switch. With the ignition in the ON position, battery positive voltage is supplied to the park/neutral position switch. When the transmission is in the PARK position the contacts in the park/neutral position switch are closed. This allows current to flow through the switch to the automatic transmission shift lock control switch. The circuit continues through the normally-closed switch to the automatic transmission shift lock control solenoid. The automatic transmission shift lock control solenoid is permanently grounded. This energizes the automatic transmission shift lock control solenoid, locking the shift linkage in the PARK position. When the driver presses the brake pedal the contacts in the automatic transmission shift lock control switch open, causing the automatic transmission shift lock control solenoid to release. This allows the shift lever to move from the PARK position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 9678 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to Restraint Systems Caution in Service Precautions. Disable the Restraint system. Refer to Restraint Systems Disabling and Enabling Zone 3 in Restraint Systems. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 9679 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the Body Control Module. 6. Enable the Restraint systems. Refer to Restraint Systems Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 9684 Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Shift Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9687 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9688 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9689 Shift Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Shift Solenoid: Diagrams 4L60-E/4L65-E 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9692 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9693 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9694 Shift Solenoid: Diagrams 4L80-E/4L85-E 1-2 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9695 2-3 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 9696 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 9697 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 9698 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 9699 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E Shift Cable: Adjustments 4L60-E/4L65-E Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 9705 7. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 9706 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. 6. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 9707 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 9708 Shift Cable: Adjustments 4L80-E/4L85-E Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 9709 7. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 9710 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. 6. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 9711 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Shift Cable: Service and Repair 4L60-E/4L65-E Automatic Transmission Range Selector Cable Replacement Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Remove the instrument panel knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges, and Warning Indicators. 3. Remove the driver's seat. 4. Pull back the carpet and insulation around the driver's area. 5. Remove the retainer securing the cable to the steering column. 6. Remove the cable end from the steering column ball stud. 7. Depress the tangs and remove the cable from the steering column bracket. 8. Remove the bolt securing the cable support to the brace. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9714 9. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. Remove the range selector cable from the support. 10. Remove the cable grommet from the floor panel. 11. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 12. Remove the clips on the cable from the floor panel reinforcement. 13. Ensure the transmission manual shaft is positioned in mechanical park. 14. Remove the retainer that secures the cable to the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9715 15. Remove the cable clip on the transfer case, if equipped. 16. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 17. Depress the tangs and remove the cable from the bracket. 18. Lower the vehicle and ensure that the steering column shift lever is still in the park position. Installation Procedure 1. Ensure that the transmission manual shaft lever is in the mechanical park position. 2. Align and install the cable to the bracket. 3. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 4. Install the cable clip on the transfer case, if equipped. 5. Install the retainer that secures the cable to the bracket. 6. Install the clips on the cable to the floor panel reinforcement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9716 7. Lower the vehicle. 8. Install the cable grommet to the floor panel. 9. Important: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. Install the range selector cable to the support. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt securing the cable support to the brace. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 11. Install the cable to the steering column bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9717 12. Ensure the tangs fully seat (snap) into the steering column bracket. 13. Install the cable end to the steering column ball stud. 14. Install the retainer securing the cable to the steering column. 15. Position the carpet and insulation around the driver's area. 16. Install the driver's seat. 17. Install the instrument panel knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and Warning Indicators. 18. Test the transmission for proper shift operation. 19. If all of the gear positions cannot be achieved, adjust the cable. Refer to Automatic Transmission Range Selector Cable Adjustment. Automatic Transmission Range Selector Cable Bracket Replacement Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Remove the retainer that secures the cable to the bracket. 5. Depress the tangs and remove the cable from the bracket. 6. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 7. Remove the transmission range selector cable bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9718 1. Install the transmission range selector cable bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission range selector cable bracket bolts (1). ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Align and install the cable to the bracket. 4. Install the retainer that secures the cable to the bracket. 5. Lower the vehicle. 6. Check the vehicle for proper operation. If cable adjustment is necessary, refer to Automatic Transmission Range Selector Cable Adjustment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9719 Shift Cable: Service and Repair 4L80-E/4L85-E Automatic Transmission Range Selector Cable Replacement Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Remove the instrument panel knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges, and Warning Indicators. 3. Remove the driver's seat. Refer to Seat Replacement - Front Bucket in Seats. 4. Pull back the carpet and insulation around the driver's area. 5. Remove the retainer securing the cable to the steering column. 6. Remove the cable end from the steering column ball stud. 7. Depress the tangs and remove the cable from the steering column bracket. 8. Remove the bolt securing the cable support to the brace. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9720 9. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. Remove the range selector cable from the support. 10. Remove the cable grommet from the floor panel. 11. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 12. Remove the clips on the cable from the floor panel reinforcement. 13. Ensure the transmission manual shaft is positioned in mechanical park. 14. Remove the retainer that secures the cable to the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9721 15. Remove the cable clip on the transfer case, if equipped. 16. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 17. Depress the tangs and remove the cable from the bracket. 18. Lower the vehicle and ensure that the steering column shift lever is still in the park position. Installation Procedure 1. Ensure that the transmission manual shaft lever is in the mechanical park position. 2. Align and install the cable to the bracket. 3. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 4. Install the cable clip on the transfer case, if equipped. 5. Install the retainer that secures the cable to the bracket. 6. Install the clips on the cable to the floor panel reinforcement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9722 7. Lower the vehicle. 8. Install the cable grommet to the floor panel. 9. Important: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. Install the range selector cable to the support. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt securing the cable support to the brace. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 11. Install the cable to the steering column bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9723 12. Ensure the tangs fully seat (snap) into the steering column bracket. 13. Install the cable end to the steering column ball stud. 14. Install the retainer securing the cable to the steering column. 15. Position the carpet and insulation around the driver's area. 16. Install the driver's seat. Refer to Seat Replacement - Front Bucket in Seats. 17. Install the instrument panel knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges, and Warning Indicators. 18. Test the transmission for proper shift operation. 19. If all of the gear positions cannot be achieved, adjust the cable. Automatic Transmission Range Selector Cable Bracket Replacement Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Disconnect the transmission range selector cable from the shift lever and the bracket (2). 5. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 6. Remove the transmission range selector cable bracket from the vehicle. Installation Procedure 1. Install the transmission range selector cable bracket to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9724 Install the transmission range selector cable bracket bolts (1). ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Install the transmission range selector cable to the bracket (2) and the lever. 4. Lower the vehicle. 5. Check the vehicle for proper operation. If adjustment of the cable is necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9733 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9734 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9740 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9741 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-017A > Aug > 06 > A/T 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise Torque Converter: Customer Interest A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise Bulletin No.: 06-07-30-017A Date: August 16, 2006 TECHNICAL Subject: 4L60-E, 4L65-E, 4L70-E Automatic Transmission High Pitched Whine, Whistle, Chirp or Buzz Type Noise at 1,500-1,800 RPM (Replace with Updated Torque Converter) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Chevrolet Corvette 2005-2006 Chevrolet Silverado, Silverado SS, SSR 2006 Chevrolet TrailBlazer SS 2005-2006 GMC Sierra, Sierra Denali, Yukon Denali, Yukon Denali XL 2005-2006 Pontiac GTO 2005-2006 HUMMER H2, H2 SUT with 4L65-E, 4L70-E Automatic Transmission (RPOs M32 or M70) 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL with 4L60-E Automatic Transmission (RPO M30) Supercede: This bulletin is being revised to update Transmission RPO usage information in the Parts table. Please discard Corporate Bulletin Number 06-07-30-017 (Section 07 - Automatic Transmission). Condition Some customers may comment on a high pitched whistle or whine type noise at approximately 1,500-1,800 rpm while in any forward gear with the torque converter clutch (TCC) disengaged. This noise is typically easier to duplicate when driving up a slight grade when accelerating. This noise will stop when the TCC is engaged. Some 2007 vehicles have been reported to exhibit this noise in 1st gear at approximately 16 km/h (10 mph) with 30-50% TPS on a launch from a stop. Cause The torque converter pump blade may cause this condition. A torque converter pump blade revision is expected in production by the end of July, 2006. Correction To determine the location of the noise, use the chassis ears with a small acoustic clip-on microphone (such as Radio Shack P/N 33-3013) plugged into the chassis ear amplifier. Drive the vehicle to duplicate the concern using the chassis ears and the Tech 2 to apply and release the TCC. If the noise is coming from the bell housing area only, when the TCC is commanded off, replace the torque converter. If the noise is present with the TCC commanded on, this noise is not caused by the torque converter and torque converter replacement will not correct the condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-017A > Aug > 06 > A/T 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 9750 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-017A > Aug > 06 > A/T 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 9751 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-017A > Aug > 06 > A/T 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 9752 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 01-07-30-010C > May > 08 > A/T - Torque Converter Replacement Information Torque Converter: All Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 01-07-30-010C > May > 08 > A/T - Torque Converter Replacement Information > Page 9758 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-017A > Aug > 06 > A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise Torque Converter: All Technical Service Bulletins A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise Bulletin No.: 06-07-30-017A Date: August 16, 2006 TECHNICAL Subject: 4L60-E, 4L65-E, 4L70-E Automatic Transmission High Pitched Whine, Whistle, Chirp or Buzz Type Noise at 1,500-1,800 RPM (Replace with Updated Torque Converter) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Chevrolet Corvette 2005-2006 Chevrolet Silverado, Silverado SS, SSR 2006 Chevrolet TrailBlazer SS 2005-2006 GMC Sierra, Sierra Denali, Yukon Denali, Yukon Denali XL 2005-2006 Pontiac GTO 2005-2006 HUMMER H2, H2 SUT with 4L65-E, 4L70-E Automatic Transmission (RPOs M32 or M70) 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL with 4L60-E Automatic Transmission (RPO M30) Supercede: This bulletin is being revised to update Transmission RPO usage information in the Parts table. Please discard Corporate Bulletin Number 06-07-30-017 (Section 07 - Automatic Transmission). Condition Some customers may comment on a high pitched whistle or whine type noise at approximately 1,500-1,800 rpm while in any forward gear with the torque converter clutch (TCC) disengaged. This noise is typically easier to duplicate when driving up a slight grade when accelerating. This noise will stop when the TCC is engaged. Some 2007 vehicles have been reported to exhibit this noise in 1st gear at approximately 16 km/h (10 mph) with 30-50% TPS on a launch from a stop. Cause The torque converter pump blade may cause this condition. A torque converter pump blade revision is expected in production by the end of July, 2006. Correction To determine the location of the noise, use the chassis ears with a small acoustic clip-on microphone (such as Radio Shack P/N 33-3013) plugged into the chassis ear amplifier. Drive the vehicle to duplicate the concern using the chassis ears and the Tech 2 to apply and release the TCC. If the noise is coming from the bell housing area only, when the TCC is commanded off, replace the torque converter. If the noise is present with the TCC commanded on, this noise is not caused by the torque converter and torque converter replacement will not correct the condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-017A > Aug > 06 > A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 9763 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-017A > Aug > 06 > A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 9764 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 06-07-30-017A > Aug > 06 > A/T - 4L60-E/4L65-E/4L70-E Whine/Whistle/Chirp Noise > Page 9765 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 01-07-30-010C > May > 08 > A/T - Torque Converter Replacement Information Torque Converter: All Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 01-07-30-010C > May > 08 > A/T - Torque Converter Replacement Information > Page 9771 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 9776 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Torque Converter Clutch Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9781 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9782 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9783 Torque Converter Clutch Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Torque Converter Clutch Solenoid: Diagrams 4L60-E/4L65-E Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9786 Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side (M30)/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9787 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9788 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector.Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9789 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9790 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9791 ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 9792 ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 9797 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 9798 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 9799 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 9800 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Cooler: Service and Repair 4L60-E/4L65-E Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Line Quick Connect Fitting . 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Line Quick Connect Fitting . 4. Install the front grill assembly. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9803 Transmission Cooler: Service and Repair 4L80-E/4L85-E Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the grille assembly. 2. Remove the transmission fluid cooler hoses from the auxiliary cooler. 3. Remove the auxiliary oil cooler bolts (1). 4. Remove the auxiliary oil cooler push pins (2) 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the bolts (1) to the radiator brace. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the push pins (2) to the radiator brace. 4. Connect the transmission oil cooler lines to the auxiliary cooler. 5. Install the grille assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E > Page 9808 Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 9811 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 9812 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 9813 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Mount: Service and Repair 4L60-E/4L65-E Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ Tighten the bolts to 50 Nm (37 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9818 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. ^ Tighten the nut or nuts to 40 Nm (30 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9819 Transmission Mount: Service and Repair 4L80-E/4L85-E Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ Tighten the bolts to 50 Nm (37 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9820 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. ^ Tighten the nut or nuts to 40 Nm (30 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 9825 Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 9828 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9831 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9832 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9833 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9834 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9835 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Speed Sensor: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9840 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9841 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9842 Transmission Speed Sensor: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E Transmission Speed Sensor: Diagrams 4L80-E/4L85-E Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 9845 Automatic Transmission Output Shaft Speed (AT OSS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 9846 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Speed Sensor: Service and Repair 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9849 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9850 Transmission Speed Sensor: Service and Repair 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9851 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9852 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9853 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E > Page 9858 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Temperature Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9861 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9862 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 9863 Transmission Temperature Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9864 Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 09-07-30-017A > May > 10 > A/T - Harsh Light Throttle 1-2 Shift Valve Body: Customer Interest A/T - Harsh Light Throttle 1-2 Shift TECHNICAL Bulletin No.: 09-07-30-017A Date: May 20, 2010 Subject: Harsh 1-2 Shift at Light Throttle (Install New 1-2 Accumulator Valve Kit) Models: 2003-2007 Cadillac Escalade 2003-2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2007 GMC Sierra, Yukon, Yukon XL All Equipped with 4.8L or 5.3L Engine (RPOs LR4, LM7, L59, LM4, LH6, L33) and 4L60E Automatic Transmission (RPO M30) Please Refer to GMVIS Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 09-07-30-017 (Section 07 - Transmission/Transaxle). Condition Some customers may comment about a harsh 1-2 shift at light throttle. Cause This condition may be caused by the 2-4 band apply time extending through the 1-2 accumulator stroke. Correction 1. Verify the customer's concern. 2. Remove the valve body. Refer to Valve Body and Pressure Switch Removal in SI. 3. Remove the coiled spring pin (360). 4. Remove the 1-2 accumulator valve sleeve (372). 5. Remove the 1-2 accumulator valve (371) and the 1-2 accumulator valve spring (370). 6. Install the new 1-2 accumulator valve kit, GM P/N 24255821. 7. Install the valve body. Refer to Valve Body and Pressure Switch Installation in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 09-07-30-017A > May > 10 > A/T - Harsh Light Throttle 1-2 Shift > Page 9873 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: Customer Interest A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 9878 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 09-07-30-017A > May > 10 > A/T - Harsh Light Throttle 1-2 Shift Valve Body: All Technical Service Bulletins A/T - Harsh Light Throttle 1-2 Shift TECHNICAL Bulletin No.: 09-07-30-017A Date: May 20, 2010 Subject: Harsh 1-2 Shift at Light Throttle (Install New 1-2 Accumulator Valve Kit) Models: 2003-2007 Cadillac Escalade 2003-2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2007 GMC Sierra, Yukon, Yukon XL All Equipped with 4.8L or 5.3L Engine (RPOs LR4, LM7, L59, LM4, LH6, L33) and 4L60E Automatic Transmission (RPO M30) Please Refer to GMVIS Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 09-07-30-017 (Section 07 - Transmission/Transaxle). Condition Some customers may comment about a harsh 1-2 shift at light throttle. Cause This condition may be caused by the 2-4 band apply time extending through the 1-2 accumulator stroke. Correction 1. Verify the customer's concern. 2. Remove the valve body. Refer to Valve Body and Pressure Switch Removal in SI. 3. Remove the coiled spring pin (360). 4. Remove the 1-2 accumulator valve sleeve (372). 5. Remove the 1-2 accumulator valve (371) and the 1-2 accumulator valve spring (370). 6. Install the new 1-2 accumulator valve kit, GM P/N 24255821. 7. Install the valve body. Refer to Valve Body and Pressure Switch Installation in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 09-07-30-017A > May > 10 > A/T - Harsh Light Throttle 1-2 Shift > Page 9884 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-015 > Mar > 08 > A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift Valve Body: All Technical Service Bulletins A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift INFORMATION Bulletin No.: 08-07-30-015 Date: March 27, 2008 Subject: Diagnostic Information on MN8, MT1 SES/MIL Illuminated, DTC P0757, Harsh Shift, Delayed 2-3 Shift, 2-3 Shift Flare, No Third Gear, Slips in Third Gear or Reverse Models: 2002-2007 Chevrolet Avalanche 2500 Series, Silverado Classic, Suburban 2500 Series 2002-2008 Chevrolet Express 2002-2007 GMC Sierra Classic, Yukon XL 2500 Series 2002-2008 GMC Savana with HYDRA‐MATIC(R)4L80‐E (RPO MT1) or4L85‐E (RPO MN8) Automatic Transmission The purpose of this bulletin is to provide technicians with additional diagnostic information on DTC P0757. Refer to Service Information (SI) for DTC P0757, 2-3 Shift Solenoid Valve Performance No Third or Fourth Gear. Additional 4L80‐E or 4L85‐E transmission symptoms may be a harsh shift, delayed 2-3 shift, no third gear or slip in third or reverse, or a 2-3 shift flare. The transmission fluid inspection may or may not indicate distressed clutches. On all 2002-2006 vehicles and certain 2007-2008 vehicles, check for any debris caught in the # 11 check ball. If debris is found, repair per Service Bulletin 08-07-30-001. Also inspect the direct clutch for damage that may have been caused by a leak in the oil circuit that may be a result of the debris. If no debris is found, and no other cause is found when referring to Service Information (SI) for DTC P0757, valve body replacement may be indicated. Also check the 2-3 shift valve for debris or leakage. If none of these items seem to have a concern, replace the 2-3 shift solenoid due to a possible sticking pintle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9897 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9898 Valve Body Spring and Bore Plug Chart (inch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9899 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9900 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9901 Left Side Control Valve Body Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9902 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9903 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9904 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 9909 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 9914 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 9915 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 9916 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 08-07-30-015 > Mar > 08 > A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift Valve Body: All Technical Service Bulletins A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift INFORMATION Bulletin No.: 08-07-30-015 Date: March 27, 2008 Subject: Diagnostic Information on MN8, MT1 SES/MIL Illuminated, DTC P0757, Harsh Shift, Delayed 2-3 Shift, 2-3 Shift Flare, No Third Gear, Slips in Third Gear or Reverse Models: 2002-2007 Chevrolet Avalanche 2500 Series, Silverado Classic, Suburban 2500 Series 2002-2008 Chevrolet Express 2002-2007 GMC Sierra Classic, Yukon XL 2500 Series 2002-2008 GMC Savana with HYDRA‐MATIC(R)4L80‐E (RPO MT1) or4L85‐E (RPO MN8) Automatic Transmission The purpose of this bulletin is to provide technicians with additional diagnostic information on DTC P0757. Refer to Service Information (SI) for DTC P0757, 2-3 Shift Solenoid Valve Performance No Third or Fourth Gear. Additional 4L80‐E or 4L85‐E transmission symptoms may be a harsh shift, delayed 2-3 shift, no third gear or slip in third or reverse, or a 2-3 shift flare. The transmission fluid inspection may or may not indicate distressed clutches. On all 2002-2006 vehicles and certain 2007-2008 vehicles, check for any debris caught in the # 11 check ball. If debris is found, repair per Service Bulletin 08-07-30-001. Also inspect the direct clutch for damage that may have been caused by a leak in the oil circuit that may be a result of the debris. If no debris is found, and no other cause is found when referring to Service Information (SI) for DTC P0757, valve body replacement may be indicated. Also check the 2-3 shift valve for debris or leakage. If none of these items seem to have a concern, replace the 2-3 shift solenoid due to a possible sticking pintle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9930 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9931 Valve Body Spring and Bore Plug Chart (inch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9932 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9933 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9934 Left Side Control Valve Body Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9935 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9936 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 9937 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 9942 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 9943 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 9944 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Valve Body: Service and Repair 4L60-E/4L65-E Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9947 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9948 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Remove the remaining valve body bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9949 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9950 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Notice: Refer to Fastener Notice in Service Precautions. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9951 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9952 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Do not install the transmission fluid indicator stop bracket and bolt at this time.Install but do not tighten the valve body bolts which retain only the valve body directly.Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9953 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9954 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9955 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9956 Valve Body: Service and Repair 4L80-E/4L85-E Valve Body and Pressure Switch Replacement ^ Tools Required J 25025-5 Valve Body Align Pin - J 36850 Transjel(R) Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body: ^ The 2-3 solenoid (1) ^ The internal wiring harness (2) ^ The 1-2 shift solenoid (3) ^ The transmission fluid temperature sensor (4) ^ The transmission fluid pressure manual valve position switch (5) ^ The pressure control solenoid (6) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (7) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wire harness from the transmission fluid pressure (TFP) manual valve position switch. Important: Use care not to loose the 5 O-rings that are located between the TFP manual valve position switch and the valve body. 5. Remove the valve body bolts (1) that retain the (TFP) manual valve position switch (2). 6. Remove the TFP manual valve position switch. 7. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9957 8. Remove the lube oil pipe bolt (6) and retainer (7). 9. Remove the lube oil pipe (5). 10. Remove the manual shaft detent spring bolt and spring (3). Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 11. Remove the remaining valve body bolts. 12. Carefully lower the valve body from the transmission. Use care not to drop the manual shaft valve. 13. Remove the valve body (2) which includes the following: ^ The accumulator housing (1) ^ The valve body to the spacer plate gasket ^ The spacer plate 14. Remove the manual valve (1) from the valve body. 15. Inspect the manual valve for nicks and burrs. 16. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate. 17. Remove the PWM screen (1) from the case passage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9958 18. Remove the manual 2-1 band servo (1). 19. Remove the servo piston cushion spring (2). 20. Remove the manual 2-1 band servo piston pin retainer ring (4). 21. Remove the manual 2-1 band servo piston pin (1). 22. Remove the manual 2-1 band servo piston seal (2). 23. Important: Do not use a magnet in order to remove the checkballs. Using a magnet to remove the checkballs may magnetize the checkballs, causing metal particles to stick. Remove the 8 checkballs (9 for some models). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9959 1. Install the 8 checkballs (9 for some models) into the transmission case passages. ^ The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only ^ To hold the checkballs in place, use the J 36850. 2. Install the PWM screen into the valve body. 3. Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3). 4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3). 5. Install the manual 2-1 band servo piston pin retainer ring (4). 6. Install the manual 2-1 band servo piston cushion spring (2). 7. Important: Make certain that the tapered end of the manual 2-1 band servo piston pin contacts the manual 2-1 band. Install the manual 2-1 band servo piston (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9960 8. Install the manual valve (1) into the valve body. 9. To aid in alignment and assembly, install J 25025-5. 10. Install the valve body gasket (6). 11. Install the valve body (5). Attach the manual valve to the detent lever while installing the valve body. 12. Install the transmission fluid pressure manual valve position switch (2). 13. Install the transmission fluid pressure manual valve position switch bolts (1) finger tight. 14. Tighten the bolts in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 15. Remove J 25025-5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 9961 16. Install the manual shaft detent roller and spring (3) and bolts. 17. Install the 2 wiring harness clips (1) and bolts (2). 18. Install the wiring harness clip (1) and bolts (2). 19. Install the lube oil pipe (5) with the short end into the valve body. 20. Install the lube oil pipe retainer (7) and the bolt (6). 21. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts and tighten in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 22. Install the remaining valve body bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness to the valve body electrical components. 24. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: Customer Interest Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 9970 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: All Technical Service Bulletins Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 9976 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Information not provided by the vehicle manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 9983 Clutch Fluid: Fluid Type Specifications HYDRAULIC CLUTCH FLUID WITH 5-SPEED TRANSMISSION Hydraulic Clutch Fluid (GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. WITH 6-SPEED TRANSMISSION Hydraulic Clutch Fluid. Use only GM Part No. U.S. 88958860, in Canada 88901244, Super DOT-4 brake fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. 3. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Remove the clutch master cylinder clip from the brake pressure module valve pipe. 5. If equipped with a ZF S6-650 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 6. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 9987 7. If equipped with a NV 3500 or NV 4500 transmission, remove the clutch master cylinder. 8. If equipped with a ZF S6-650 transmission, remove the clutch master cylinder. Installation Procedure 1. If equipped with a ZF S6-650 transmission, install the clutch master cylinder. 2. If equipped with a NV 3500 or NV 4500 transmission, install the clutch master cylinder. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 9988 3. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. 4. If equipped with a ZF S6-650 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 5. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 6. Install the clutch master cylinder clip to the brake pressure module valve pipe. 7. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 8. Connect the clutch pedal position switch electrical connector (1). 9. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > NV3500/NV4500 Transmissions Clutch Slave Cylinder: Service and Repair NV3500/NV4500 Transmissions Clutch Actuator Cylinder Replacement (NV3500/NV4500 Transmissions) Removal Procedure 1. Remove the manual transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. If required, the clutch release bearing can be removed from the clutch actuator cylinder for replacement. Installation Procedure 1. Install the clutch actuator cylinder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the clutch actuator cylinder bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 3. Install the manual transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > NV3500/NV4500 Transmissions > Page 9993 Clutch Slave Cylinder: Service and Repair ZF S6-650 Transmission Clutch Actuator Cylinder Replacement (ZF S6-650 Transmission) Removal Procedure 1. Remove the manual transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. If required, the clutch release bearing can be removed from the clutch actuator cylinder for replacement. Installation Procedure 1. Install the clutch actuator cylinder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the clutch actuator cylinder bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 3. Install the manual transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair Clutch Pedal Replacement Removal Procedure 1. Remove the driver's side knee bolster and deflector. 2. Disconnect and reposition the junction block. 3. Disconnect the clutch pedal position switch electrical connector (1). 4. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. 5. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch master cylinder to clutch actuator cylinder quick connect fitting. 6. Remove the clutch master cylinder clip from the brake pressure module valve pipe. 7. If equipped with a ZF S6-650 transmission, disconnect the clutch master cylinder to clutch actuator cylinder quick connect fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 9997 8. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. Important: Complete removal of the clutch master cylinder is not required. 9. Pull the clutch master cylinder out until the pushrod socket is not touching the clutch pedal. 10. Remove the clutch pedal to clutch pedal bracket bolt. 11. Remove the clutch pedal to brake module bolts. 12. Remove the clutch pedal sub-assembly. Installation Procedure 1. Install the clutch pedal sub-assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 9998 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the clutch pedal to brake module bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 3. Install the clutch pedal to clutch pedal bracket bolt. ^ Tighten the bolt to 36 Nm (27 ft. lbs.). 4. Push the clutch master cylinder in until the pushrod socket is touching the clutch pedal. 5. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. 6. If equipped with a ZF S6-650 transmission, connect the clutch master cylinder to clutch actuator cylinder quick connect fitting. 7. If equipped with a NV 3500 or NV 4500 transmission, connect the clutch master cylinder to clutch actuator cylinder quick connect fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 9999 8. Install the clutch master cylinder clip to the brake pressure module valve pipe. 9. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 10. Connect the clutch pedal position switch electrical connector (1). 11. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. 12. Position and connect the junction block. 13. Install the driver's side knee bolster and deflector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Clutch Start Switch Clutch Start Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 10004 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 10005 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 10006 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair Release Bearing Replacement Removal Procedure 1. Remove the manual transmission. 2. Remove the clutch release bearing. ^ Rotate the bearing in either direction ^ The compression spring load will push the release bearing off the end of the clutch actuator bearing. Installation Procedure Important: DO NOT use cleaners or chemicals to clean the quill and DO NOT grease the quill. 1. Using a clean dry cloth, clean the exposed area of the actuator cylinder quill. 2. Install the NEW clutch release bearing to the clutch actuator cylinder. ^ Firmly push the clutch release bearing into place. ^ The release bearing will snap over the retainer tab and will be self-retained to the actuator cylinder. 3. Install the manual transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Pilot Bearing Replacement ^ Tools Required J 43276 Clutch Pilot Bearing Remover - J 38836 Bushing Installer/Clutch Arbor Removal Procedure Notice: When using the J 43276 Clutch Pilot Bearing Remover, always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 tool body to rotate. Failing to do so causes damage to the J 43276-1 tool body. Important: The flywheel spacer (if applicable) must be removed prior to clutch pilot bearing removal. 1. Remove the clutch assembly. 2. Using J 43276 perform the following in order to remove the clutch pilot bearing: 1. Install the J 43276-1 into the clutch pilot bearing. 2. Using a wrench, secure the J 43276-1. 3. Insert the J 43276-2 into the J 43276-1. 4. Rotate the J 43276-2 clockwise into the J 43276-1 until the clutch pilot bearing is completely removed from the crankshaft. 5. Rotate the J 43276-2 counterclockwise to remove the J 43276-2 from the J 43276-1. 6. Remove the J 43276-1 from the tool body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 10013 3. Discard the old clutch pilot bearing. Installation Procedure Important: The flywheel spacer (if applicable) must be removed prior to pilot bearing installation. 1. Install a 5/8 inch washer (1) onto the J 38836 or equivalent. 2. Install a NEW clutch pilot bearing (2) onto the tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 10014 3. Install the NEW clutch pilot bearing into the crankshaft using J 38836. 4. Inspect the clutch pilot bearing for proper installation. 5. Install the clutch assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure Plate Bolt .............................................................................................................................. ...................................................... 70 Nm (52 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 10018 Pressure Plate: Adjustments Clutch Pressure Plate Adjustment (Off-Vehicle (6.0L, 6.6L, 8.1L Only)) Important: ^ Use the following procedure when replacing ONLY the clutch disc. The self adjusting clutch pressure plate/cover assembly must be "reset" back to the "unworn" position in order to work properly. Failure to "reset" the cover assembly results in the inability to achieve full clutch release and clutch slippage under full torque. ^ The 6.6L engine uses a "potted" style flywheel, and the cover stamping is much shorter to accommodate the flywheel, as a result to "reset" this clutch the cover MUST be evenly supported at all six bolt holes in order to keep from bending the cover and to unload the adjuster ring allowing the clutch to be "reset." 1. Place the clutch pressure plate and disc, flange side down, on a press. 2. Compress the pressure plate diaphragm spring fingers until tension is released from the stepped adjusting ring. 3. Using 2 screwdrivers or other suitable tools, place them against 2 of the 3 stepped adjusting ring tension spring stops (1), just ahead of the adjusting ring tension springs. 4. Using the screwdrivers, rotate the stepped adjusting ring counterclockwise (compressing the tension springs) until the adjusting ring steps are fully adjusted out, then continue to hold in position. 5. Release the press pressure from the pressure plate diaphragm spring fingers. 6. Release the adjusting ring tension spring stops. 7. Remove the pressure plate and disc from the press. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > Customer Interest for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: Customer Interest Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > Customer Interest for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle > Page 10034 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: All Technical Service Bulletins Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle > Page 10040 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Differential Side Bearings Replacement (All Except 9.75 Inch Axle) Carrier Bearings: Service and Repair Differential Side Bearings Replacement (All Except 9.75 Inch Axle) Differential Side Bearings Replacement (All Except 9.75 Inch Axle) ^ Tools Required J 22912-01Split Plate Bearing Puller - J 8092 Universal Driver Handle - 3⁄4 in - 10 - J 21784 Side Bearing Installer - J 22888-D Side Bearing Remover Kit - J 29710 Differential Side Bearing Installer - J 36597 Side Bearing Puller Pilot - 9.25 Axle - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Remove the differential assembly. 2. Remove the differential side bearings by doing the following: 1. For the 8.6 inch, 9.5 inch, 11.5 inch axles, install the differential assembly into a vise. 2. For the 10.5 inch axle, place a block of wood on each side of the differential assembly. Install the differential assembly into a vise. 3. Install the J 22888-20A (2) and the J 8107-4, 8.6 inch axle, or the J 36597, 9.5 inch or 10.5 inch axle, or the J 8107-5, 11.5 inch (1) axle, over the differential case side bearing bore. 4. Remove the differential side bearings using the J 22888-20A. Installation Procedure 1. For the 8.6 inch, the 9.5 inch, and the 10.5 inch axles, install the differential side bearings by doing the following: 1. In order to protect the differential case, install the J 8107-4, 8.6 inch axle, or the J 36597, 9.5 inch or 10.5 inch axles, in the case on the side opposite the bearing installation. 2. Install the J 21784, 8.6 inch axle, or the J 29710, 9.5 inch or 10.5 inch axles (2), and the J 8092 (1) onto the differential case bearing as shown. 3. Drive the bearing onto the case using the J 21784 or the J 29710 and the J 8092. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Differential Side Bearings Replacement (All Except 9.75 Inch Axle) > Page 10043 2. For the 11.5 inch axle, install the differential side bearings by doing the following: 1. In order to protect the differential case, install the J 8107-5 in the case on the side opposite the bearing installation. 2. Install the J 44420 (2) and the J 8092 (1) onto the differential case bearing as shown. 3. Drive the bearing onto the case using the J 44420 and the J 8092. 3. Install the differential assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Differential Side Bearings Replacement (All Except 9.75 Inch Axle) > Page 10044 Carrier Bearings: Service and Repair Differential Side Bearings Replacement (9.75 Inch Axle) Differential Side Bearings Replacement (9.75 Inch Axle) ^ Tools Required J 22888-D Side Bearing Remover Kit - J 24430 Differential Side Bearing Installer - J 36597 Side Bearing Puller Pilot - 9.25 inch - J 45711 Differential Side Bearing Remover - Dana 248 - J 45900 Differential Side Bearing Installer - Dana Axles - J 8092 Universal Driver Handle - 3/4 in - 10 Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the differential side bearing by performing the following steps: 1. Install the J 45711 (2) and the J 36597 (1) as shown. 2. Remove the differential side bearing using the J 45711 and a hydraulic press. 4. Remove the inboard shims. Important: Mark the inboard shims left or right. Installation Procedure 1. Determine the shim thickness and preload for the differential assembly. 2. Install the differential side bearing by doing the following: 1. In order to protect the differential case, install the J 8107-3 in the case on the side opposite of the bearing installation. 2. Install the inboard shims. 3. Install the differential side bearing. 4. Install the J 24430 or the J 45900 (2) and the J 8092 (1) over the differential side bearing. 5. Drive the differential side bearing into position using the J 24430 or the J 45900 and the J 8092. 6. Install the differential assembly. 3. Fill the axle with lubricant. Use the proper fluid. 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 03-04-19-004B > Dec > 05 > Drivetrain - Growl/Moan Noise From Front Axle Differential Case: Customer Interest Drivetrain - Growl/Moan Noise From Front Axle Bulletin No.: 03-04-19-004B Date: December 12, 2005 TECHNICAL Subject: Growl or Moan Noise Coming From Front Axle (Replace Front Axle Differential Case) Models: 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with 4WD and Active Transfer Case (RPO NP8) and 8.25 Inch Front Axle Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 03-04-19-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a growl or moan-type noise coming from the front axle above 50 km/h (30 mph). This condition may be described as a noise that phases or cycles in and out. This noise is present in the 2WD mode only, and may be present whether the vehicle is accelerating, decelerating, or at a steady speed. The noise goes away in 4WD or Auto 4WD modes. Cause This noise may be caused by a low clearance condition within the differential in the front axle assembly. In the 2WD mode, the front differential has a large amount of relative motion between the differential pinion and side gears. In the 4WD or Auto 4WD modes, the transfer case motors the front propeller shaft, and the relative motion between the differential gears is reduced or eliminated, so the noise is eliminated. Correction Replace the front differential case, P/N 26018131. This is the component bolted to the ring gear. It is NOT necessary to replace the differential gears unless unusual wear is observed. Use the procedure listed below. 1. Raise the vehicle. 2. Remove the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the Service Manual. 3. Drain the differential carrier assembly. 4. Disconnect the electrical connector from the actuator and wire harness from the right inner axle shaft housing and differential carrier. 5. Remove the right wheel driveshaft inboard flange bolts from the inner axle shaft. 6. Disconnect the right wheel driveshaft from the inner axle shaft. 7. Remove the inner axle shaft housing nuts from the bracket. 8. Remove the inner axle shaft housing bolts from the differential carrier assembly. 9. Carefully remove the inner axle shaft housing assembly from the differential carrier. 10. Remove the left wheel driveshaft inboard flange bolts from the inner axle shaft. 11. Remove the left inner axle shaft from the differential carrier assembly. 12. Remove the front drive axle clutch shaft from the differential carrier assembly. 13. Remove the differential carrier assembly bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 03-04-19-004B > Dec > 05 > Drivetrain - Growl/Moan Noise From Front Axle > Page 10053 14. Separate the right carrier case half from the left carrier case half. 15. Remove the differential case assembly from the carrier. 16. Place the differential case in a vise. 17. Remove the differential side bearings using the J 22888-20A. 18. Remove the differential case from the vise. Important: The ring gear bolts have left-hand threads. 19. Remove the ring gear bolts. 20. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary. 21. Remove the pinion shaft pin. Use a hammer and a drift pin in order to drive out the pin. 22. Remove the pinion shaft. 23. Roll the differential pinion gears out of the case with the pinion gear thrust washers. 24. Remove the differential side gears and the side gear thrust washers. Mark the pinion gears and thrust washers top and bottom and the differential side gears and thrust washers left and right. 25. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to the Maintenance and Lubrication subsection. 26. Install the differential side gear thrust washers to the differential side gears. 27. Install the differential side gears and thrust washers into the new differential case. 28. Install the differential pinion gears and thrust washers by performing the following steps: 28.1. Position one pinion gear between the differential side gears. 28.2. Position the second pinion gear between the differential side gear directly opposite of the first gear. 28.3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case. 28.4. Install the thrust washers. Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers. 29. Install the pinion gear shaft. 30. Install the pinion gear shaft lock pin using a hammer and a brass drift. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 03-04-19-004B > Dec > 05 > Drivetrain - Growl/Moan Noise From Front Axle > Page 10054 31. Install the ring gear onto the differential case. 32. Install the ring gear bolts. Hand start each bolt to ensure that the ring gear is properly seated to the differential case. 33. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 120 N.m (88 lb ft). 34. Install the differential side bearings by performing the following steps: 34.1. In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation. 34.2. Install the J 22761(2) and the J 8092 (1) onto the differential case bearing as shown. 34.3. Drive the differential case bearing onto the case using the J 22761 and the J 8092. 35. Install the new differential case assembly into the carrier. 36. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all grease and oil. 37. Apply a bead of sealer, P/N 1052942 (Canadian P/N 10953466), or equivalent, to one differential carrier case half sealing surface. 38. Install the right differential carrier case half. 39. Install the differential carrier case bolts Tighten Tighten the differential carrier case bolts to 47 N.m (35 lb ft). 40. Install the front drive axle clutch shaft to the differential carrier. 41. Install the left side inner axle shaft by doing the following steps: 41.1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. 41.2. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. 41.3. Drive the inner into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. 42. Apply sealant, P/N 1052942 (Canadian P/N 10953466), or equivalent, to the inner axle housing to differential carrier sealing surface. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 03-04-19-004B > Dec > 05 > Drivetrain - Growl/Moan Noise From Front Axle > Page 10055 43. Install the right inner axle shaft housing assembly to the differential carrier assembly. 44. Install the inner axle shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft). 45. Install the inner axle shaft housing washers and nuts to the bracket. Tighten Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft). 46. Connect the wheel drive shaft inboard flange to the inner axle shaft. 47. Install the wheel drive shaft inboard flange to the inner axle shaft bolts. Tighten Tighten the wheel drive shaft inboard flange to the inner axle shaft bolts to 79 N.m (58 lb ft). 48. Connect the wire harness to the inner axle shaft housing and differential carrier. 49. Connect the electrical connector to the front axle actuator. 50. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Replacement - Front Drive Axle in the Front Axle sub-section of the Service Manual. 51. Install the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the service manual. 52. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 03-04-19-004B > Dec > 05 > Drivetrain - Growl/Moan Noise From Front Axle > Page 10056 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 03-04-19-004B > Dec > 05 > Drivetrain - Growl/Moan Noise From Front Axle Differential Case: All Technical Service Bulletins Drivetrain - Growl/Moan Noise From Front Axle Bulletin No.: 03-04-19-004B Date: December 12, 2005 TECHNICAL Subject: Growl or Moan Noise Coming From Front Axle (Replace Front Axle Differential Case) Models: 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with 4WD and Active Transfer Case (RPO NP8) and 8.25 Inch Front Axle Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 03-04-19-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a growl or moan-type noise coming from the front axle above 50 km/h (30 mph). This condition may be described as a noise that phases or cycles in and out. This noise is present in the 2WD mode only, and may be present whether the vehicle is accelerating, decelerating, or at a steady speed. The noise goes away in 4WD or Auto 4WD modes. Cause This noise may be caused by a low clearance condition within the differential in the front axle assembly. In the 2WD mode, the front differential has a large amount of relative motion between the differential pinion and side gears. In the 4WD or Auto 4WD modes, the transfer case motors the front propeller shaft, and the relative motion between the differential gears is reduced or eliminated, so the noise is eliminated. Correction Replace the front differential case, P/N 26018131. This is the component bolted to the ring gear. It is NOT necessary to replace the differential gears unless unusual wear is observed. Use the procedure listed below. 1. Raise the vehicle. 2. Remove the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the Service Manual. 3. Drain the differential carrier assembly. 4. Disconnect the electrical connector from the actuator and wire harness from the right inner axle shaft housing and differential carrier. 5. Remove the right wheel driveshaft inboard flange bolts from the inner axle shaft. 6. Disconnect the right wheel driveshaft from the inner axle shaft. 7. Remove the inner axle shaft housing nuts from the bracket. 8. Remove the inner axle shaft housing bolts from the differential carrier assembly. 9. Carefully remove the inner axle shaft housing assembly from the differential carrier. 10. Remove the left wheel driveshaft inboard flange bolts from the inner axle shaft. 11. Remove the left inner axle shaft from the differential carrier assembly. 12. Remove the front drive axle clutch shaft from the differential carrier assembly. 13. Remove the differential carrier assembly bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 03-04-19-004B > Dec > 05 > Drivetrain - Growl/Moan Noise From Front Axle > Page 10062 14. Separate the right carrier case half from the left carrier case half. 15. Remove the differential case assembly from the carrier. 16. Place the differential case in a vise. 17. Remove the differential side bearings using the J 22888-20A. 18. Remove the differential case from the vise. Important: The ring gear bolts have left-hand threads. 19. Remove the ring gear bolts. 20. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary. 21. Remove the pinion shaft pin. Use a hammer and a drift pin in order to drive out the pin. 22. Remove the pinion shaft. 23. Roll the differential pinion gears out of the case with the pinion gear thrust washers. 24. Remove the differential side gears and the side gear thrust washers. Mark the pinion gears and thrust washers top and bottom and the differential side gears and thrust washers left and right. 25. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to the Maintenance and Lubrication subsection. 26. Install the differential side gear thrust washers to the differential side gears. 27. Install the differential side gears and thrust washers into the new differential case. 28. Install the differential pinion gears and thrust washers by performing the following steps: 28.1. Position one pinion gear between the differential side gears. 28.2. Position the second pinion gear between the differential side gear directly opposite of the first gear. 28.3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case. 28.4. Install the thrust washers. Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers. 29. Install the pinion gear shaft. 30. Install the pinion gear shaft lock pin using a hammer and a brass drift. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 03-04-19-004B > Dec > 05 > Drivetrain - Growl/Moan Noise From Front Axle > Page 10063 31. Install the ring gear onto the differential case. 32. Install the ring gear bolts. Hand start each bolt to ensure that the ring gear is properly seated to the differential case. 33. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 120 N.m (88 lb ft). 34. Install the differential side bearings by performing the following steps: 34.1. In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation. 34.2. Install the J 22761(2) and the J 8092 (1) onto the differential case bearing as shown. 34.3. Drive the differential case bearing onto the case using the J 22761 and the J 8092. 35. Install the new differential case assembly into the carrier. 36. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all grease and oil. 37. Apply a bead of sealer, P/N 1052942 (Canadian P/N 10953466), or equivalent, to one differential carrier case half sealing surface. 38. Install the right differential carrier case half. 39. Install the differential carrier case bolts Tighten Tighten the differential carrier case bolts to 47 N.m (35 lb ft). 40. Install the front drive axle clutch shaft to the differential carrier. 41. Install the left side inner axle shaft by doing the following steps: 41.1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. 41.2. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. 41.3. Drive the inner into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. 42. Apply sealant, P/N 1052942 (Canadian P/N 10953466), or equivalent, to the inner axle housing to differential carrier sealing surface. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 03-04-19-004B > Dec > 05 > Drivetrain - Growl/Moan Noise From Front Axle > Page 10064 43. Install the right inner axle shaft housing assembly to the differential carrier assembly. 44. Install the inner axle shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft). 45. Install the inner axle shaft housing washers and nuts to the bracket. Tighten Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft). 46. Connect the wheel drive shaft inboard flange to the inner axle shaft. 47. Install the wheel drive shaft inboard flange to the inner axle shaft bolts. Tighten Tighten the wheel drive shaft inboard flange to the inner axle shaft bolts to 79 N.m (58 lb ft). 48. Connect the wire harness to the inner axle shaft housing and differential carrier. 49. Connect the electrical connector to the front axle actuator. 50. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Replacement - Front Drive Axle in the Front Axle sub-section of the Service Manual. 51. Install the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the service manual. 52. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 03-04-19-004B > Dec > 05 > Drivetrain - Growl/Moan Noise From Front Axle > Page 10065 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair Differential Cover: Service and Repair Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the rear axle. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Remove the rear axle housing cover (2) from the axle housing. 1. Catch the oil in a drain pan. 2. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. Installation Procedure 1. Install the rear axle housing cover (2) and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the new rear axle housing cover bolts (1). ^ Tighten the rear axle housing cover bolts in a crosswise pattern to 40 Nm (30 ft. lbs.). Important: Do not reuse the rear axle housing cover bolts. 3. Fill the rear axle. Use the proper fluid. 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 10073 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Information not provided by manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 10076 Fluid - Differential: Fluid Type Specifications DIFFERENTIAL FLUID Front Axle - Four-Wheel Drive SAE 80W-90 Axle Lubricant (GM Part No. U.S. 1052271, in Canada 10950849). Front Axle - All-Wheel Drive SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 12378261, in Canada 10953455) meeting GM Specification 9986115. Rear Axle SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 12378261, in Canada 10953455) meeting GM Specification 9986115. Rear Axle - Steerable Synthetic Axle Lubricant; use only GM Part No. U.S. 12378557, in Canada 88901362.Do not add friction modifier. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant Fluid - Differential: Service and Repair When to Check Lubricant When to Check Lubricant It is not necessary to regularly check front or rear axle fluid unless you suspect there is a leak or you hear an unusual noise. A fluid loss could indicate a problem. Have it inspected and repaired. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 10079 Fluid - Differential: Service and Repair Front Drive Axle Lubricant Level Inspection Lubricant Level Inspection - Front Drive Axle 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. ^ For the 8.25 inch axle, the oil level should be between 12-16 mm (0.50-0.625 inch) below the fill plug opening. ^ For the 9.25 inch axle, the oil level should be between 0-6 mm (0-0.25 inch) below the fill plug opening. 7. If the level is low, add oil until the level is between 12-16 mm (0.50-0.625 inch) for the 8.25 inch axle or 0-6 mm (0-0.25 inch) for the 9.25 inch axle. Use the correct fluid. 8. Install the fill plug. ^ Tighten the plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Lower the vehicle. Lubricant Replacement Lubricant Replacement - Front Drive Axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the front differential carrier shield, if equipped. 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 10080 Installation Procedure 1. Install the drain plug. ^ Tighten the drain plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. 3. Install the fill plug. ^ Tighten the fill plug to 33 Nm (24 ft. lbs.). 4. Install the front differential carrier shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 10081 Fluid - Differential: Service and Repair Rear Differential Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". 7. Insert the pipe cleaner into the fill plug opening with the stem facing down. 8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The distance between the bend and the lubricant level should be 15 - 40 mm (0.6 - 1.6 inch). 9. If the measurement is greater than 40 mm (1.6 inch), add lubricant until the level is between 15 40 mm (0.6 - 1.6 inch) from the bottom edge of the fill plug hole. Use the proper fluid. 10. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Service Precautions. 11. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (9.5/9.5LD, 10.5 Inch Axles) Lubricant Level Inspection - Rear Drive Axle (9.5/9.5LD, 10.5 Inch Axles) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 10082 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Notice: Refer to Service Precautions. 9. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (9.75 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (9.75 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0 - 4 mm (0 - 0.16 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). Notice: Refer to Service Precautions. 9. Lower the vehicle. Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17 - 21 mm (0.6 - 0.8 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is between 17 - 21 mm (0.6 - 0.8 inch) below the fill plug opening. Use the proper fluid. 8. Install the rear axle fill plug and gasket. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 10083 Notice: Refer to Service Precautions. 9. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) Removal Procedure 1. Raise the vehicle. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Carefully remove the rear axle housing cover (2) and drain the lubricant into a suitable container. 5. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. 6. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation is an indication of extreme wear. Installation Procedure 1. Install a new gasket and the rear axle housing cover (2). 2. Install the new rear axle housing cover bolts (1). ^ Tighten the bolts to 40 Nm (30 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 10084 Notice: Refer to Service Precautions. Important: Do not reuse the rear axle housing cover bolts. 3. Fill the rear axle. Use the proper fluid. 4. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle) Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 10085 1. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 27 Nm (20 ft. lbs.). Notice: Refer to Service Precautions. 2. Fill the rear axle. Use the proper fluid. 3. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 4. Lower the vehicle. Lubricant Replacement - Rear Drive Axle (9.5/9.5LD, 10.5, and 11.5 Inch Axles) Lubricant Replacement - Rear Drive Axle (9.5/9.5LD, 10.5, and 11.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. For the 9.5/9.5LD and the 10.5 inch axles, remove the rear axle fill plug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 10086 3. For the 11.5 inch axle, remove the fill plug. 4. Remove the rear axle drain plug. 5. Drain the lubricant into a suitable container. 6. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 7. Clean the drain plug. Installation Procedure 1. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 33 Nm (24 ft. lbs.). Notice: Refer to Service Precautions. 2. Fill the rear axle. Use the proper fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > When to Check Lubricant > Page 10087 3. For the 9.5/9.5LD and the 10.5 inch axles, install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 4. For the 11.5 inch axle, install the seal and the fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Pinion Bearing: Service and Repair Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Rear Differential Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) ^ Tools Required J 7818 Inner Bearing Race Installer, 9.5/9.5LD inch axle - J 8092 Driver Handle 3⁄4 in - 10 - J 8608 Rear Pinion Bearing Race Installer, 8.6 inch, 11.5 inch axle - J 8611-01 Rear Pinion Bearing Race Installer - J 8614-01 Flange and Pulley Holding Tool - J 22306 Pinion Cup Bearing Installer - Rear, 9.5/9.5LD inch axle - J 22388 Rear Axle Pinion Oil Seal Installer, 8.6 inch, 9.5/9.5LD inch axle - J 22912-01 Split Plate Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer, 8.6 inch axle - J 36614 Inner Pinion Bearing Installer, 9.5/9.5LD inch axle - J 44412 Pinion Bearing Installer, 11.5 inch axle - J 44414 Rear Axle Pinion Oil Seal Installer, 11.5 inch axle - J 44417 Rear Pinion Bearing Race Installer, 11.5 inch axle - J 45871 Pinion Bearing Remover - J 45900 Pinion Bearing Cup Installer, 8.6 in axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the drive pinion from the axle. 4. For the 8.6 inch axle, install the J 45871 (1) around the pinion bearing and the J 22912-01 (2) in the inverted position around the J 45871. 5. Press the bearing off of the pinion using the J 45871 and the J 22912-01. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10092 6. For the 9.5/9.5LD inch and 11.5 inch axles, press the bearing off of the pinion using the J 22912-01. 7. Remove the shim. 8. Remove the outer pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10093 9. Remove the inner pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Installation Procedure 1. Install the outer pinion bearing cup using the J 8611-01, 8.6 inch axle, or the J 7818, 9.5/9.5LD inch axle, or the J 8608 (11.5 inch axle) (2) and the J 8092 (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10094 2. Install the inner pinion bearing cup using the J 45900, 8.6 inch axle, or the J 22306, 9.5/9.5LD inch axle, or the J 44417, 11.5 inch axle (2) and the J 8092 (1). 3. Determine the selective shim thickness for the pinion. 4. Install the selective shim between the inner pinion bearing and the shoulder on the gear. 5. Install the inner pinion bearing using the J 24433, 8.6 inch axle, or the J 36614, 9.5/9.5LD inch axle, or the J 44412, 11.5 inch axle. Press the bearing on until the cone seats on the pinion shim. 6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 8. Install the outer pinion bearing into the axle housing. 9. Install a new pinion oil seal using the J 22388, 8.6 inch, 9.5/9.5LD inch axles, or the J 44414, 11.5 inch axle. 10. Install the pinion into the axle housing. 11. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the splines of the pinion yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10095 12. Install the pinion yoke. Align the marks made during removal. 13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 14. Install the washer and a new pinion nut. 15. Install the J 8614-01 onto the pinion yoke as shown. 16. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 17. Measure the rotating torque of the pinion using an inch-pound torque wrench. The rotating torque of the pinion should be between 1.0 - 2.3 Nm (10 - 20 inch lbs.) for used bearings, or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings. 18. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) for used bearings, or 1.7 Nm (15 inch lbs.) for new bearings, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is between 1.0 - 2.3 Nm (10 - 20 inch lbs.) for used bearings, or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings. 19. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Inspect the rotating torque and adjust if necessary. 20. Install the differential assembly. 21. Fill the axle with lubricant. Use the proper fluid. 22. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10096 Pinion Bearing: Service and Repair Drive Pinion Bearings Replacement (9.75 Inch Axle) Rear Differential Drive Pinion Bearings Replacement (9.75 Inch Axle) ^ Tools Required J 22536 Pinion Driver - J 22912-01 Split-Plate Bearing Puller - J 42176 Universal Driver Handle - Non-Threaded - J 45703 Pinion Bearing Race Remover - Dana 248 - J 45704 Pinion Bearing Race Installer - Dana 248 - J 45705 Pinion Bearing Race Remover - Dana 248/267 - J 7818 Inner Bearing Race Installer - J 8092 Universal Drive Handle - 3⁄4 in - 10 Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion yoke and the pinion oil seal. 4. Remove the thrust washer. 5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 6. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 7. Remove the pinion preload shims from the drive pinion and set aside. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10097 8. Remove the inner pinion bearing cup and the oil deflector using the J 45703 (2) and the J 42176 (1). 9. Remove the outer pinion bearing cup using the J 45705 and the J 42176. 10. Remove the inner pinion bearing using the J 22912-01 and a hydraulic press. 11. Remove the pinion position shim. Installation Procedure 1. Install the oil deflector into the inner pinion cup bore. 2. Install the inner pinion bearing cup using the J 45704 (2) and the J 8092 (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10098 3. Install the outer pinion bearing cup using the J 7818 (2) and the J 8092 (1). 4. Determine the pinion position shim thickness and the pinion preload shim thickness for the drive pinion. 5. Install the differential assembly. 6. Fill the axle with lubricant. Use the proper fluid. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10099 Pinion Bearing: Service and Repair Drive Pinion Bearings Replacement (10.5 Inch Axle) Rear Differential Drive Pinion Bearings Replacement (10.5 Inch Axle) ^ Tools Required J 22388 Pinion Oil Seal Installer - Rear - J 22761 Differential Side Bearing Installer - J 22912-01 Split Plate Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer - J 37624 Pinon Bearing Installer - J 8092 Universal Driver Handle - 3⁄4 in - 10 - J 8608 Rear Pinion Bearing Installer - J 8614-01 Flange and Pulley Holding Tool Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion gear bearing retainer. 4. Remove the pinion yoke and the oil seal. 5. Remove the outer pinion bearing. 6. Remove the pinion. 7. Remove the collapsible spacer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10100 8. Remove the inner pinion bearing from the pinion using the J 22912-01 and a hydraulic press. 9. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 10. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 11. Remove the pinion gear pilot bearing using a brass drift and a hammer. Installation Procedure 1. Install the pinion gear pilot bearing using the J 22761. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10101 2. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). 3. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). 4. Install the inner pinion bearing using the J 24433. Press the bearing on until the cone seats on the pinion. 5. Install a new collapsible spacer. 6. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 7. Install the outer pinion bearing into the pinion bearing retainer. 8. Install a new pinion oil seal using the J 22388. 9. Install the pinion into the pinion gear bearing retainer. 10. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10102 11. Install the pinion yoke. Align the marks made during removal. 12. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 13. Install the washer and a new pinion nut. 14. Install the J 8614-01 onto the pinion yoke. 15. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 16. Remove the J 8614-01. 17. Install the original shim to the pinion bearing retainer. If the original shim is not available, install a 0.41 mm (0.016 inch) shim to build pinion depth. Important: Do not apply sealant to the pinion gear bearing retainer at this time. 18. Install the pinion gear bearing retainer to the axle housing. 19. Install the pinion bearing retainer bolts. ^ Tighten the pinion gear retainer bolts to 88 Nm (65 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10103 20. Measure the rotating torque of the pinion using an inch-pound torque wrench. The rotating torque of the pinion should be between 1.0 - 2.3 Nm (10 - 20 inch lbs.) for used bearings, or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings. 21. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) for used bearings, or 1.7 Nm (15 inch lbs.) for new bearings, install the J 8614-01 and continue to tighten the pinion nut.Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is between 1.0 - 2.3 Nm (10 - 20 inch lbs.) for used bearings, or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings. 22. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 23. Install the differential assembly. 24. Adjust the differential side bearing preload. 25. Determine the selective shim thickness for the drive pinion. 26. Adjust the backlash. 27. Fill the axle with lubricant. Use the proper fluid. 28. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle Pinion Flange: Service and Repair Front Drive Axle Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 36366 Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake calipers. 4. Remove the differential carrier assembly shield, if equipped. 5. Reference mark the relationship of the propeller shaft to the front axle pinion yoke. 6. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). 7. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 8. Support the propeller shaft and move out of the way as necessary. 9. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion seal ^ The carrier bearings Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10108 ^ The axle bearings ^ The axle seals 10. Scribe an alignment line between the pinion shaft and the pinion yoke. 11. Install the J 8614-01 onto the pinion as shown. 12. Remove the pinion nut while holding the J 8614-01. 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). 15. Remove the oil seal using a suitable seal removal tool. Important: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10109 1. Install the oil seal by doing the following: 1. Position the oil seal over the seal bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 3. Install the pinion yoke. Align the reference marks made during removal. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Measure the rotating torque of the pinion using an inch-pound torque wrench.Compare the measurement with the rotating torque recorded earlier. ^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 inch lbs.) greater than the torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10110 10. Install the propeller shaft universal joint (2) to the pinion yoke (1).Align the reference marks made during removal. 11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 12. Inspect the axle lubricant level, and add, if necessary. 13. Install the differential carrier assembly shield, if equipped. 14. Install the brake calipers. 15. Install the tire and wheel assemblies. 16. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10111 Pinion Flange: Service and Repair Rear Differential Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) ^ Tools Required J 8614-01 Flange/Pulley Holding Tool - J 22388 Rear Axle Pinion Oil Seal Installer - Rear (8.6 inch, 9.5 inch axle) - J 44414 Rear Axle Pinion Oil Seal Installer (10.5 inch, 11.5 inch axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 2. Remove the tire and wheel assemblies (8.6 inch, 9.5 inch axles). 3. Remove the rear brake calipers (8.6 inch, 9.5 inch axles). 4. Remove the brake rotors (8.6 inch, 9.5 inch axles). 5. Remove the axle shafts (10.5 inch, 11.5 inch axle). 6. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 7. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 8. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing (10.5 inch axle) ^ The pinion oil seal ^ The differential case bearings ^ The axle bearings (8.6 inch, 9.5 inch axles) ^ The axle seals (8.6 inch, 9.5 inch axles) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10112 9. Place an alignment mark between the pinion and the pinion yoke. 10. Install the J 8614-01 as shown. 11. Remove the pinion nut while holding the J 8614-01. 12. Remove the washer. 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 15. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388 (8.6 inch, 9.5 inch axles) or the J 44414 (10.5 inch, 11.5 inch axle). 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10113 3. Install the pinion yoke. Align the marks made during removal. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten the nut in small increments, as needed, until the rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). 12. Install the axle shafts (10.5 inch, 11.5 inch axle). 13. Install the brake rotors (8.6 inch, 9.5 inch axles). 14. Install the brake calipers (8.6 inch, 9.5 inch axles). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10114 15. Install the tire and wheel assemblies. 16. Inspect and add axle lubricant to the axle housing, if necessary. 17. Lower the vehicle. Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 45710 Pinion Bearing Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 2. Disconnect the propeller shaft from the rear axle pinion yoke. 3. Place an alignment mark between the pinion and the pinion yoke. 4. Install the J 8614-01 as shown. 5. Remove the pinion nut while holding the J 8614-01. 6. Remove the washer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10115 7. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 8. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 9. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the axle housing. Installation Procedure 1. Apply a light coat of axle lubricant, GM P/N 12378557 or equivalent meeting GM Specification 9986207, to the lip of the pinion seal. 2. Install the new seal using the J 45710. 3. Install the pinion yoke. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10116 5. Install the washer. 6. Install the new pinion nut 7. Install the J 8614-01 onto the pinion yoke as shown. 8. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut to 370 Nm (273 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Install the propeller shaft to the rear axle pinion yoke. 10. Inspect and add axle lubricant to the axle housing, if necessary. 11. Lower the vehicle. Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle W/Drum Brakes) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle w/Drum Brakes) ^ Tools Required J 8614-01 Flange/Pulley Holding Tool - J 22388 Rear Axle Pinion Oil Seal Installer - Rear Removal Procedure Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10117 removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 3. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 4. Using an inch-pound torque wrench, measure the amount of torque required to rotate the pinion. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion oil seal ^ The differential case bearings ^ The axle bearings ^ The axle seals 5. Place an alignment mark between the pinion and the pinion yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10118 6. Install the J 8614-01 as shown. 7. While holding the J 8614-01, loosen the pinion nut. 8. Remove the washer. 9. Remove the pinion nut and washer. 10. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 11. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10119 12. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. 3. Install the pinion yoke. Align the marks made during removal. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 10120 Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer and a NEW pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten the nut in small increments, as needed, until the rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts.Tighten the bolts to 25 Nm (18 ft. lbs.). 12. Inspect and add axle lubricant to the axle housing, if necessary. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement Pinion Gear: Service and Repair Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement ^ Tools Required J 44414 Pinion Seal Installer - J 22912-01 Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer - J 37624 Pinion Bearing Installer - J 8092 Driver Handle - J 8608 Rear Pinion Bearing Race Installer - J 8614-01 Flange/Pulley Holding Tool Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 2. Drain the axle lubricant. 3. Remove the axle shafts. 4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 5. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 6. Measure the amount of torque required to rotate the pinion and the ring gear. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing ^ The pinion oil seal ^ The differential case bearings Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10125 7. Place an alignment mark between the pinion and the pinion yoke. 8. Remove the pinion gear bearing retainer bolts. 9. Remove the pinion gear bearing retainer and the pinion. 10. Remove the selective shim. 11. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. 12. Install the J 8614-01 as shown. 13. Remove the pinion nut while holding the J 8614-01. 14. Remove the washer. 15. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 (3) as shown. 16. Remove the pinion yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 (3). 17. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. 18. Remove the outer pinion bearing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10126 19. Remove the pinion. 20. Remove the collapsible spacer. 21. Remove the inner pinion bearing from the pinion using the J 22912-01 and a hydraulic press. 22. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 23. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10127 1. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). 2. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). 3. Install the inner pinion bearing using the J 24433.Press the bearing on until the cone seats on the pinion. 4. Install a new collapsible spacer. 5. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 6. Install the pinion into the pinion gear bearing retainer. 7. Install the outer pinion bearing onto the pinion. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10128 8. Install a new pinion oil seal using the J 44414. 9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 10. Install the pinion yoke. Align the marks made during removal. 11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 12. Install the washer and a new pinion nut. 13. Install the J 8614-01 onto the pinion yoke as shown. 14. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 15. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. ^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 Nm (3-5 inch lbs.) greater than the rotating torque recorded during removal. 16. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10129 17. Determine the selective shim thickness for the pinion gear bearing retainer. 18. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to sealing surface of the pinion gear bearing retainer. 19. Install the selective shim.Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer. 20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to surface of the selective shim. 21. Install the pinion gear bearing retainer. 22. Install the pinion gear bearing retainer bolts. ^ Tighten the pinion gear bearing retainer bolts to 88 Nm (65 ft. lbs.). 23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal. The rotating torque of the pinion and the ring gear should be between 3.9-6.2 Nm (30-55 inch lbs.) for new bearings or 2.8-5.6 Nm (25-50 inch lbs.) for used bearings. 24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary. 25. Install the propeller shaft (3) to the pinion yoke (4).Align the reference marks made during removal. 26. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). 27. Install the axle shafts. 28. Fill the axle with axle lubricant. 29. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10130 Pinion Gear: Service and Repair Rear Differential Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) ^ Tools Required J 22536 Pinion Driver, 8.6 inch, 9.5/9.5LD inch axles - J 44421 Pinion Remover, 11.5 inch axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion yoke and the oil seal. 4. Install the J 22536, 8.6 inch or 9.5/9.5LD inch axle, or the J 44421, 11.5 inch axle as shown. Ensure that the J 22536 or the J 44421 is firmly seated on the pinion. 5. Drive the pinion out using the J 22536 or the J 44421 and a hammer. Strike the J 22536 or the J 44421 slowly. Do not let the pinion fall out of the rear axle housing. 6. Remove the collapsible spacer from the pinion. Discard the spacer. 7. Remove the pinion bearings and the cups. 8. Remove the gear bolts. Discard the bolts. Important: The ring gear bolts on the 8.6 inch and the 9.5/9.5LF inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. 9. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10131 1. Install the ring gear to the differential case. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Important: The ring gear bolts on the 8.6 inch and the 9.5/9.5LD inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. 3. Tighten the ring gear bolts, Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 Nm (89 ft. lbs.). ^ For the 9.5/9.5LD inch axles, tighten the ring gear bolts in sequence to 140 Nm (103 ft. lbs.). ^ For the 11.5 inch axle, tighten the ring gear bolts in sequence to 237 Nm (175 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the pinion bearing cups. 5. Determine the selective shim thickness for the pinion gear. 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing to the pinion. 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. 10. Install the outer pinion bearing into the axle housing. 11. Install the new pinion oil seal. 12. Install the pinion into the axle housing. 13. Install the pinion yoke. 14. Install the differential assembly. 15. Fill the axle with lubricant. Use the proper fluid. 16. Lower the vehicle. Drive Pinion and Ring Gear Replacement (9.75 Inch Axle) Drive Pinion and Ring Gear Replacement (9.75 Inch Axle) ^ Tools Required J 22536 Pinion Driver Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10132 3. Remove the drive pinion yoke and the pinion oil seal. 4. Remove the thrust washer. 5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 6. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 7. Remove the pinion preload shims from the drive pinion and set aside. 8. Remove the inner pinion bearing and the pinion position shim. 9. Remove the ring gear bolts. Discard the bolts. Important: The ring gear bolts have right-hand threads. 10. Remove the ring gear from the differential case. Drive the gear off with a brass drift if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10133 Notice: Refer to Ring Gear Removal Notice in Service Precautions. Installation Procedure 1. Determine the pinion position shim thickness and the pinion preload shim thickness for the drive pinion gear. 2. Install the ring gear to the differential case. Align the holes in the differential case to the bolts holes in the ring gear. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 3. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Important: The ring gear bolts have right-hand threads. 4. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ Tighten the new ring gear bolts to 178 Nm (131 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the differential assembly. 6. Fill the axle with lubricant. Use the proper fluid. 7. Lower the vehicle. Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion gear bearing retainer. 4. Remove the pinion and the pinion bearings. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10134 5. Remove the ring gear bolts. Discard the bolts. Important: The ring gear bolts have left-hand threads. 6. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case as shown. 2. Install the ring gear to the differential case. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 3. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Important: The ring gear bolts have left-hand threads. 4. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ Tighten the ring gear bolts in sequence to 165 Nm (122 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the pinion and the pinion bearings. 6. Install the pinion gear bearing retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 10135 7. Install the differential assembly. 8. Fill the axle with lubricant. Use the proper fluid. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Ring Gear: Service and Repair Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Rear Differential Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) ^ Tools Required J 22536 Pinion Driver, 8.6 inch, 9.5/9.5LD inch axles - J 44421 Pinion Remover, 11.5 inch axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion yoke and the oil seal. 4. Install the J 22536, 8.6 inch or 9.5/9.5LD inch axle, or the J 44421, 11.5 inch axle as shown. Ensure that the J 22536 or the J 44421 is firmly seated on the pinion. 5. Drive the pinion out using the J 22536 or the J 44421 and a hammer. Strike the J 22536 or the J 44421 slowly. Do not let the pinion fall out of the rear axle housing. 6. Remove the collapsible spacer from the pinion. Discard the spacer. 7. Remove the pinion bearings and the cups. 8. Remove the gear bolts. Discard the bolts. Important: The ring gear bolts on the 8.6 inch and the 9.5/9.5LF inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. 9. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10140 1. Install the ring gear to the differential case. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Important: The ring gear bolts on the 8.6 inch and the 9.5/9.5LD inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. 3. Tighten the ring gear bolts, Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 Nm (89 ft. lbs.). ^ For the 9.5/9.5LD inch axles, tighten the ring gear bolts in sequence to 140 Nm (103 ft. lbs.). ^ For the 11.5 inch axle, tighten the ring gear bolts in sequence to 237 Nm (175 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the pinion bearing cups. 5. Determine the selective shim thickness for the pinion gear. 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing to the pinion. 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. 10. Install the outer pinion bearing into the axle housing. 11. Install the new pinion oil seal. 12. Install the pinion into the axle housing. 13. Install the pinion yoke. 14. Install the differential assembly. 15. Fill the axle with lubricant. Use the proper fluid. 16. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10141 Ring Gear: Service and Repair Drive Pinion and Ring Gear Replacement (9.75 Inch Axle) Rear Differential Drive Pinion and Ring Gear Replacement (9.75 Inch Axle) ^ Tools Required J 22536 Pinion Driver Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the drive pinion yoke and the pinion oil seal. 4. Remove the thrust washer. 5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 6. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 7. Remove the pinion preload shims from the drive pinion and set aside. 8. Remove the inner pinion bearing and the pinion position shim. 9. Remove the ring gear bolts. Discard the bolts. Important: The ring gear bolts have right-hand threads. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10142 10. Remove the ring gear from the differential case. Drive the gear off with a brass drift if necessary. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Installation Procedure 1. Determine the pinion position shim thickness and the pinion preload shim thickness for the drive pinion gear. 2. Install the ring gear to the differential case. Align the holes in the differential case to the bolts holes in the ring gear. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 3. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Important: The ring gear bolts have right-hand threads. 4. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ Tighten the new ring gear bolts to 178 Nm (131 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the differential assembly. 6. Fill the axle with lubricant. Use the proper fluid. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10143 Ring Gear: Service and Repair Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Rear Differential Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion gear bearing retainer. 4. Remove the pinion and the pinion bearings. 5. Remove the ring gear bolts. Discard the bolts. Important: The ring gear bolts have left-hand threads. 6. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case as shown. 2. Install the ring gear to the differential case. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) > Page 10144 3. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Important: The ring gear bolts have left-hand threads. 4. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the ring gear bolts in sequence to 165 Nm (122 ft. lbs.). 5. Install the pinion and the pinion bearings. 6. Install the pinion gear bearing retainer. 7. Install the differential assembly. 8. Fill the axle with lubricant. Use the proper fluid. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle Seals and Gaskets: Service and Repair Front Drive Axle Inner Axle Seal and/or Bearing Replacement Inner Axle Seal and/or Bearing Replacement - Front Drive Axle ^ Tools Required J 8092 Universal Driver Handle - 3⁄4 in - 10 - J 2619-01 Slide Hammer - J 29369-1 Bushing and Bearing Remover - J 29369-2 Bushing and Bearing Remover (2-3 inch) - J 36609 Axle Tube Bearing Installer - J 45225 Axle Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the differential carrier assembly. 3. Remove the right side seal and/or bearing by performing the following steps: 1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly. 2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. 3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. 4. Install the J 29369-1, 8.25 inch axle, or the J 29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01. 4. If replacing the left side seal, perform the following steps: 1. Place an alignment mark between the inner axle shaft and the wheel drive shaft. 2. Disconnect the wheel drive shaft from the inner axle shaft. 3. Remove the inner axle shaft using a hammer and brass drift. 4. Remove the inner axle shaft seal using a suitable seal remover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10149 5. Remove the left side seal and bearing by performing the following steps: 1. Remove the differential carrier assembly. 2. Place the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case. 3. Remove the inner axle shaft using a hammer and a brass drift. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2, 9.25 inch axle (1), behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2. 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01. Installation Procedure 1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10150 2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 3. Install the inner axle shaft into the inner axle shaft housing.Carefully tap the inner axle shaft into place with a soft-faced mallet. 4. Install the clutch fork assembly components. 5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. 6. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10151 7. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 8. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. 9. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 10. Install the front differential carrier assembly. 11. Fill the differential carrier assembly. Use the correct fluid. 12. Lower the vehicle. Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 36366 Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake calipers. 4. Remove the differential carrier assembly shield, if equipped. 5. Reference mark the relationship of the propeller shaft to the front axle pinion yoke. 6. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). 7. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10152 Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 8. Support the propeller shaft and move out of the way as necessary. 9. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion seal ^ The carrier bearings ^ The axle bearings ^ The axle seals 10. Scribe an alignment line between the pinion shaft and the pinion yoke. 11. Install the J 8614-01 onto the pinion as shown. 12. Remove the pinion nut while holding the J 8614-01. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10153 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). 15. Remove the oil seal using a suitable seal removal tool. Important: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case. Installation Procedure 1. Install the oil seal by doing the following: 1. Position the oil seal over the seal bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 3. Install the pinion yoke. Align the reference marks made during removal. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10154 7. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Measure the rotating torque of the pinion using an inch-pound torque wrench.Compare the measurement with the rotating torque recorded earlier. ^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 inch lbs.) greater than the torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft universal joint (2) to the pinion yoke (1).Align the reference marks made during removal. 11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 12. Inspect the axle lubricant level, and add, if necessary. 13. Install the differential carrier assembly shield, if equipped. 14. Install the brake calipers. 15. Install the tire and wheel assemblies. 16. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10155 Seals and Gaskets: Service and Repair Rear Differential Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle W/Drum Brakes) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle w/Drum Brakes) ^ Tools Required J 8614-01 Flange/Pulley Holding Tool - J 22388 Rear Axle Pinion Oil Seal Installer - Rear Removal Procedure Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 3. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 4. Using an inch-pound torque wrench, measure the amount of torque required to rotate the pinion. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion oil seal ^ The differential case bearings ^ The axle bearings ^ The axle seals Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10156 5. Place an alignment mark between the pinion and the pinion yoke. 6. Install the J 8614-01 as shown. 7. While holding the J 8614-01, loosen the pinion nut. 8. Remove the washer. 9. Remove the pinion nut and washer. 10. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10157 11. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 12. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. 3. Install the pinion yoke. Align the marks made during removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10158 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer and a NEW pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten the nut in small increments, as needed, until the rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts.Tighten the bolts to 25 Nm (18 ft. lbs.). 12. Inspect and add axle lubricant to the axle housing, if necessary. 13. Lower the vehicle. Rear Axle Housing Cover and Gasket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10159 Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the rear axle. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Remove the rear axle housing cover (2) from the axle housing. 1. Catch the oil in a drain pan. 2. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. Installation Procedure 1. Install the rear axle housing cover (2) and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the new rear axle housing cover bolts (1). ^ Tighten the rear axle housing cover bolts in a crosswise pattern to 40 Nm (30 ft. lbs.). Important: Do not reuse the rear axle housing cover bolts. 3. Fill the rear axle. Use the proper fluid. 4. Lower the vehicle. Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 45710 Pinion Bearing Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10160 which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 2. Disconnect the propeller shaft from the rear axle pinion yoke. 3. Place an alignment mark between the pinion and the pinion yoke. 4. Install the J 8614-01 as shown. 5. Remove the pinion nut while holding the J 8614-01. 6. Remove the washer. 7. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 8. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 9. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the axle housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10161 Installation Procedure 1. Apply a light coat of axle lubricant, GM P/N 12378557 or equivalent meeting GM Specification 9986207, to the lip of the pinion seal. 2. Install the new seal using the J 45710. 3. Install the pinion yoke. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer. 6. Install the new pinion nut Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10162 7. Install the J 8614-01 onto the pinion yoke as shown. 8. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut to 370 Nm (273 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Install the propeller shaft to the rear axle pinion yoke. 10. Inspect and add axle lubricant to the axle housing, if necessary. 11. Lower the vehicle. Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) ^ Tools Required J 8614-01 Flange/Pulley Holding Tool - J 22388 Rear Axle Pinion Oil Seal Installer - Rear (8.6 inch, 9.5 inch axle) - J 44414 Rear Axle Pinion Oil Seal Installer (10.5 inch, 11.5 inch axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 2. Remove the tire and wheel assemblies (8.6 inch, 9.5 inch axles). 3. Remove the rear brake calipers (8.6 inch, 9.5 inch axles). 4. Remove the brake rotors (8.6 inch, 9.5 inch axles). 5. Remove the axle shafts (10.5 inch, 11.5 inch axle). 6. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 7. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10163 8. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing (10.5 inch axle) ^ The pinion oil seal ^ The differential case bearings ^ The axle bearings (8.6 inch, 9.5 inch axles) ^ The axle seals (8.6 inch, 9.5 inch axles) 9. Place an alignment mark between the pinion and the pinion yoke. 10. Install the J 8614-01 as shown. 11. Remove the pinion nut while holding the J 8614-01. 12. Remove the washer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10164 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 15. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388 (8.6 inch, 9.5 inch axles) or the J 44414 (10.5 inch, 11.5 inch axle). 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. 3. Install the pinion yoke. Align the marks made during removal. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten the nut in small increments, as needed, until the rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the rotating torque recorded during removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10165 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). 12. Install the axle shafts (10.5 inch, 11.5 inch axle). 13. Install the brake rotors (8.6 inch, 9.5 inch axles). 14. Install the brake calipers (8.6 inch, 9.5 inch axles). 15. Install the tire and wheel assemblies. 16. Inspect and add axle lubricant to the axle housing, if necessary. 17. Lower the vehicle. Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement ^ Tools Required J 44414 Pinion Seal Installer - J 22912-01 Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer - J 37624 Pinion Bearing Installer - J 8092 Driver Handle - J 8608 Rear Pinion Bearing Race Installer - J 8614-01 Flange/Pulley Holding Tool Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 2. Drain the axle lubricant. 3. Remove the axle shafts. 4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 5. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10166 shaft as necessary. 6. Measure the amount of torque required to rotate the pinion and the ring gear. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing ^ The pinion oil seal ^ The differential case bearings 7. Place an alignment mark between the pinion and the pinion yoke. 8. Remove the pinion gear bearing retainer bolts. 9. Remove the pinion gear bearing retainer and the pinion. 10. Remove the selective shim. 11. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. 12. Install the J 8614-01 as shown. 13. Remove the pinion nut while holding the J 8614-01. 14. Remove the washer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10167 15. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 (3) as shown. 16. Remove the pinion yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 (3). 17. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. 18. Remove the outer pinion bearing. 19. Remove the pinion. 20. Remove the collapsible spacer. 21. Remove the inner pinion bearing from the pinion using the J 22912-01 and a hydraulic press. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10168 22. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 23. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. Installation Procedure 1. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). 2. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10169 3. Install the inner pinion bearing using the J 24433. Press the bearing on until the cone seats on the pinion. 4. Install a new collapsible spacer. 5. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 6. Install the pinion into the pinion gear bearing retainer. 7. Install the outer pinion bearing onto the pinion. 8. Install a new pinion oil seal using the J 44414. 9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 10. Install the pinion yoke. Align the marks made during removal. 11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 12. Install the washer and a new pinion nut. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10170 13. Install the J 8614-01 onto the pinion yoke as shown. 14. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 15. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. ^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the rotating torque recorded during removal. 16. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 17. Determine the selective shim thickness for the pinion gear bearing retainer. 18. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to sealing surface of the pinion gear bearing retainer. 19. Install the selective shim. Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer. 20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to surface of the selective shim. 21. Install the pinion gear bearing retainer. 22. Install the pinion gear bearing retainer bolts. ^ Tighten the pinion gear bearing retainer bolts to 88 Nm (65 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 10171 23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal. The rotating torque of the pinion and the ring gear should be between 3.9 - 6.2 Nm (30 - 55 inch lbs.) for new bearings or 2.8 - 5.6 Nm (25 - 50 inch lbs.) for used bearings. 24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary. 25. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 26. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). 27. Install the axle shafts. 28. Fill the axle with axle lubricant. 29. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement (W/Rear Disc) Axle Bearing: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement (W/Rear Disc) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) ^ Tools Required J 8092 Universal Driver Handle-3/4 in - 10 - J 21128 Axle Pinion Oil Seal Installer (8.6 inch and 9.5 inch LD Axles) - J 23690 Axle Shaft Bearing Installer (8.6 inch and 9.5 inch LD Axles) - J 2619-01 Slide Hammer - J 29709 Wheel Bearing Installer (9.5 inch Axle) - J 29712 Wheel Bearing Remover (9.5 inch Axle) - J 29713 Axle Seal Installer (9.5 inch Axle) - J 44685 Rear Axle Seal and Bearing Remover (8.6 inch and 9.5 inch LD Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch and 9.5 inch LD axles) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (8.6 inch and 9.5 inch LD axles) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement (W/Rear Disc) > Page 10177 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128 (8.6 inch and 9.5 inch LD axles) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement (W/Rear Disc) > Page 10178 Axle Bearing: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement (W/Rear Drum) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) ^ Tools Required J 8092 Universal Driver Handle-3/4 in - 10 - J 21128 Axle Pinion Oil Seal Installer - J 23690 Axle Shaft Bearing Installer - J 2619-01 Slide Hammer - J 44685 Rear Axle Seal and Bearing Remover Removal Procedure 1. Remove the axle shaft. 2. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (1) and the J 2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement (W/Rear Disc) > Page 10179 3. Install the axle shaft seal using the J 21128. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) Axle Shaft: Service and Repair Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the rear cover and the gasket. 5. Remove the pinion shaft locking bolt. 6. On axles without a locking differential, remove the pinion shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) > Page 10185 7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing. 8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2). 9. Push the flange of the axle shaft (1) toward the differential. 10. Remove the C-lock (4) from the button end of the axle shaft (1). 11. Remove the axle shaft (1) from the housing (5). Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) > Page 10186 Installation Procedure 1. Install the axle shaft (1) into the rear axle housing (5). Important: Carefully insert the axle shaft in order to not damage the seal. 2. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear. 3. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1). 4. On axles with a locking differential, keep the pinion shaft partially withdrawn. 5. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2). 6. Pull the shaft flange outward in order to seat the lock in the differential gear. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) > Page 10187 7. Align the hole in the pinion shaft with the bolt hole in the differential case. 8. Install the new pinion shaft locking bolt. ^ For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 Nm (27 ft. lbs.). ^ For the 9.5/9.6LD inch axle, tighten the pinion shaft locking bolt to 50 Nm (37 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Install the rear cover and the gasket. 10. Install the brake caliper. 11. Install the tire and wheel assembly. 12. Fill the rear axle. Use the proper fluid. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) > Page 10188 Axle Shaft: Service and Repair Rear Axle Shaft Replacement (9.75 Inch Axle) Rear Axle Shaft Replacement (9.75 Inch Axle) Removal Procedure 1. Release the park brake. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Remove the rear steering gear assembly. 5. Remove the steering knuckle assembly. 6. Remove the lock clip from the axle shaft end. The lock clip is spring loaded and fits securely in the axle shaft slot and may need to be push off the shaft end with a screw driver or related tool. Pushing the axle shaft inwards towards the gears my help in removal of the lock clip. 7. Remove the axle shaft. Important: When removing the axle shaft do not rotate the shaft. Rotating the shaft will cause the gears to move. Misalignment of the gears will make the assembly difficult. Installation Procedure 1. Install the axle shaft. 2. Install the spring loaded lock clip to the axle shaft end. 3. Install the steering knuckle assembly. 4. Install the rear steering gear assembly. 5. Install the tire and wheel assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) > Page 10189 Axle Shaft: Service and Repair Rear Axle Shaft Replacement (8.6 Inch Axle W/Drum Brakes Rear Axle Shaft Replacement (8.6 Inch Axle w/Drum Brakes) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the rear cover and gasket. 4. Remove the pinion shaft locking bolt. 5. On axles without a locking differential, remove the pinion shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) > Page 10190 6. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing. 7. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2). 8. Remove the brake drum. 9. Push the flange of the axle shaft in toward the differential. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) > Page 10191 10. Remove the C-lock from the button end of the axle shaft. 11. Remove the axle shaft from the housing. Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make assembly difficult. Installation Procedure 1. Install the axle shaft into the rear axle housing. Important: Carefully insert the axle shaft in order to not damage the seal. 2. Slide the axle shaft into place allowing the splines to engage the differential side gear. 3. On axles without a locking differential, place the C-lock on the button end of the axle shaft. 4. On axles with a locking differential, keep the pinion shaft partially withdrawn. 5. Install the brake drum. 6. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2). 7. Pull the shaft flange outward in order to seat the lock in the differential gear. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) > Page 10192 8. Align the hole in the pinion shaft with the bolt hole in the differential case. 9. Install the new pinion shaft locking bolt. ^ Tighten the bolt to 34 Nm (25 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 10. Install the rear cover and the gasket. 11. Install the tire and wheel assembly. 12. Fill the rear axle, using the proper fluid. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) > Page 10193 Axle Shaft: Service and Repair Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Removal Procedure 1. Remove the flange bolts. 2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 3. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal. 4. Remove the axle shaft from the tube. 5. Remove the gasket. 6. Clean the axle shaft flange and the outside face of the hub assembly. Installation Procedure 1. Install the gasket onto the axle shaft. 2. Install the gasket and the axle shaft into the axle tube. 1. Ensure the shaft splines mesh into the differential side gear. 2. Align the holes in the axle flange and the gasket with the holes in the hub. 3. Install the axle flange bolts. ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 Nm (115 ft. lbs.). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 Nm (148 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Inspect and add axle lubricant to the axle housing, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement Constant Velocity Joint: Service and Repair Inner Joint and Seal Replacement Wheel Drive Shaft Inner Joint and Seal Replacement ^ Tools Required J 35910 Seal Clamp Tool - J 36652 Drive Axle Clamp Swage Tool - J 36652-98 Axle Swage Tool Disassembly Procedure 1. Use a hand grinder in order to cut through the swage ring (2). Important: Use caution when using the hand grinder by the tripot housing (1). 2. Remove the tripot housing (1) from the halfshaft. 3. Wipe the grease off of the housing (1). 4. Thoroughly degrease the tripot housing (1). 5. Allow the tripot housing (1) to dry prior to assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10198 6. Using side cutters, remove the small boot retaining clamp. 7. Remove the following items from the halfshaft bar: 1. The spacer ring (1) 2. The tripot spider assembly (2) 3. The tripot boot (3) 8. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and trunnion. Inspect the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate service kit. Assembly Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10199 1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar. 2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. 3. Secure the small seal clamp (1) with J 35910 , or equivalent, a breaker bar, and a torque wrench. ^ Tighten the small seal clamp (1) to 136 Nm (100 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10200 5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions: ^ 2-5 for the 1500 model (except 1500 HD) ^ 2-4 for the 1500 HD, 2500, 3500, and Hummer H2 models. Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10201 6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10202 8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10203 9. Assemble the tripot housing and the tripot seal using the following procedure: 1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 2. Slide the distorted swage ring (2) over the large diameter of the seal. 3. Place the tripot housing over the spider assembly. 4. Install the seal onto the tripot housing. 5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10204 10. For the 1500 models (except 1500 HD), assemble the bolts and the support plate to the base of the J-36652-01 and secure the base in a vise. 11. For the 1500 HD, 2500, 3500, and HUMMER H2 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10205 12. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and Hummer H2 models. 13. Install the top half of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and HUMMER H2 models. 14. Align the swage ring (2) and the swage ring clamp. 15. Insert the bolts. Hand tighten the bolts until the bolts are snug. 16. Align the following during this procedure: ^ The tripot boot (3) ^ The tripot housing (1) ^ The swage ring (2) ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half . ^ Loosen the bolts and remove the halfshaft assembly from the tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10206 17. Inspect the inboard stroke position. ^ Use measurement A for the 1500 models (except 1500 HD). ^ Use measurement B for the 1500 HD, 2500, 3500, and Hummer H2 models. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10207 18. Remove the convolute retainer tool from the boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10208 Constant Velocity Joint: Service and Repair Outer Joint and Seal Replacement Wheel Drive Shaft Outer Joint and Seal Replacement ^ Tools Required J 8059 Snap Ring Pliers - J 35910 Seal Clamp Tool - J 36652 Drive Axle Clamp Swage Tool Disassembly Procedure 1. Use a hand grinder to cut through the swage ring (2). Important: Use caution when using the hand grinder by the CV joint outer race (1). 2. Use side cutters to cut off the small boot clamp (4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10209 3. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 4. Wipe all grease away from the face of the CV joint. 5. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 6. Spread the snap ring ears apart using J 8059 (or equivalent). 7. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 8. Discard the old CV joint boot (5). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10210 9. Place a brass drift against the CV joint cage (1). 10. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 11. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 12. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 13. Repeat this process to remove all six of the balls. 14. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 15. Lift out the cage (4) and the inner race. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10211 16. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 17. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 18. Dry all the parts. 19. Check the CV joint assembly for unusual wear, cracks, or other damage. 20. Replace any damaged parts. 21. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Assembly Procedure 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10212 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10213 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10214 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. 16. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. ^ Tighten the small clamp (1) to 136 Nm (100 ft. lbs.). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10215 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. Pull on the CV joint (4) to verify engagement. Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 21. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 22. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 23. Mount the base of J 36652 in a vise. 24. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10216 25. Align the following during this procedure: ^ The CV joint boot (3) ^ The CV joint assembly (1) ^ The swage ring (2) 26. Install the top half of J 36652 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 27. Align the swage ring (2) and the swage ring clamp. 28. Insert the bolts into J 36652. Hand tighten the bolts until the bolts are snug. ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J 36652 touch the bottom half of the tool. 29. Loosen the bolts and remove the halfshaft assembly from J 36652. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement Constant Velocity Joint Boot: Service and Repair Inner Joint and Seal Replacement Wheel Drive Shaft Inner Joint and Seal Replacement ^ Tools Required J 35910 Seal Clamp Tool - J 36652 Drive Axle Clamp Swage Tool - J 36652-98 Axle Swage Tool Disassembly Procedure 1. Use a hand grinder in order to cut through the swage ring (2). Important: Use caution when using the hand grinder by the tripot housing (1). 2. Remove the tripot housing (1) from the halfshaft. 3. Wipe the grease off of the housing (1). 4. Thoroughly degrease the tripot housing (1). 5. Allow the tripot housing (1) to dry prior to assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10221 6. Using side cutters, remove the small boot retaining clamp. 7. Remove the following items from the halfshaft bar: 1. The spacer ring (1) 2. The tripot spider assembly (2) 3. The tripot boot (3) 8. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and trunnion. Inspect the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate service kit. Assembly Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10222 1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar. 2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. 3. Secure the small seal clamp (1) with J 35910 , or equivalent, a breaker bar, and a torque wrench. ^ Tighten the small seal clamp (1) to 136 Nm (100 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10223 5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions: ^ 2-5 for the 1500 model (except 1500 HD) ^ 2-4 for the 1500 HD, 2500, 3500, and Hummer H2 models. Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10224 6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10225 8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10226 9. Assemble the tripot housing and the tripot seal using the following procedure: 1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 2. Slide the distorted swage ring (2) over the large diameter of the seal. 3. Place the tripot housing over the spider assembly. 4. Install the seal onto the tripot housing. 5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10227 10. For the 1500 models (except 1500 HD), assemble the bolts and the support plate to the base of the J-36652-01 and secure the base in a vise. 11. For the 1500 HD, 2500, 3500, and HUMMER H2 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10228 12. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and Hummer H2 models. 13. Install the top half of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and HUMMER H2 models. 14. Align the swage ring (2) and the swage ring clamp. 15. Insert the bolts. Hand tighten the bolts until the bolts are snug. 16. Align the following during this procedure: ^ The tripot boot (3) ^ The tripot housing (1) ^ The swage ring (2) ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half . ^ Loosen the bolts and remove the halfshaft assembly from the tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10229 17. Inspect the inboard stroke position. ^ Use measurement A for the 1500 models (except 1500 HD). ^ Use measurement B for the 1500 HD, 2500, 3500, and Hummer H2 models. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10230 18. Remove the convolute retainer tool from the boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10231 Constant Velocity Joint Boot: Service and Repair Outer Joint and Seal Replacement Wheel Drive Shaft Outer Joint and Seal Replacement ^ Tools Required J 8059 Snap Ring Pliers - J 35910 Seal Clamp Tool - J 36652 Drive Axle Clamp Swage Tool Disassembly Procedure 1. Use a hand grinder to cut through the swage ring (2). Important: Use caution when using the hand grinder by the CV joint outer race (1). 2. Use side cutters to cut off the small boot clamp (4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10232 3. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 4. Wipe all grease away from the face of the CV joint. 5. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 6. Spread the snap ring ears apart using J 8059 (or equivalent). 7. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 8. Discard the old CV joint boot (5). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10233 9. Place a brass drift against the CV joint cage (1). 10. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 11. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 12. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 13. Repeat this process to remove all six of the balls. 14. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 15. Lift out the cage (4) and the inner race. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10234 16. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 17. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 18. Dry all the parts. 19. Check the CV joint assembly for unusual wear, cracks, or other damage. 20. Replace any damaged parts. 21. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Assembly Procedure 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10235 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10236 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10237 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. 16. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. ^ Tighten the small clamp (1) to 136 Nm (100 ft. lbs.). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10238 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. Pull on the CV joint (4) to verify engagement. Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 21. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 22. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 23. Mount the base of J 36652 in a vise. 24. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 10239 25. Align the following during this procedure: ^ The CV joint boot (3) ^ The CV joint assembly (1) ^ The swage ring (2) 26. Install the top half of J 36652 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 27. Align the swage ring (2) and the swage ring clamp. 28. Insert the bolts into J 36652. Hand tighten the bolts until the bolts are snug. ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J 36652 touch the bottom half of the tool. 29. Loosen the bolts and remove the halfshaft assembly from J 36652. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10253 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10254 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10255 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer Seals and Gaskets: Service and Repair Rear Axle Shaft Seal Replacement - Outer Rear Axle Shaft Seal Replacement - Outer Removal Procedure 1. Raise the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the axle shaft. 4. Remove the axle shaft seal. Installation Procedure 1. Install the axle shaft seal. 2. Install the axle shaft. 3. Install the tire and wheel assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10258 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal Replacement - Inner Rear Axle Shaft Seal Replacement - Inner ^ Tools Required J 33049 Camshaft Bearing Service Set - J 45177 Differential Seal Installer - Inner Removal Procedure 1. Raise the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the axle shafts. 4. Remove the differential assembly. 5. Install the smallest expanding driver (3) and the small driving washer (1) onto the expander assembly (2). 6. Align the separation lines between the expanding driver and the expander assembly. 7. Assemble the expander assembly (2) onto the driver bar extension (1). 8. Assemble the drive bar extension onto the driver bar. 9. Insert the J 33049 into the axle tube and through the axle shaft seal. 10. While holding the expander assembly nut, turn the driving bar clockwise until the expanding driver is snug against the axle shaft seal. 11. Drive out the seal using the J 33049 and a hammer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10259 Installation Procedure 1. Assemble the drive bar extension onto the drive bar of J 33049. 2. Insert the J 33049 into the opposite side axle shaft tube. 3. Install the J 45177 onto the J 33049. 4. Insert the axle shaft seal into the axle tube. 5. Install the J 45177 (1) and the J 33049 (2) over the axle shaft seal. 6. Drive the axle shaft seal into the axle tube using the J 45177, the J 33049 and a hammer. 7. Install the differential assembly. 8. Install the axle shafts. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10260 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement (W/Rear Disc) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) ^ Tools Required J 8092 Universal Driver Handle-3/4 in - 10 - J 21128 Axle Pinion Oil Seal Installer (8.6 inch and 9.5 inch LD Axles) - J 23690 Axle Shaft Bearing Installer (8.6 inch and 9.5 inch LD Axles) - J 2619-01 Slide Hammer - J 29709 Wheel Bearing Installer (9.5 inch Axle) - J 29712 Wheel Bearing Remover (9.5 inch Axle) - J 29713 Axle Seal Installer (9.5 inch Axle) - J 44685 Rear Axle Seal and Bearing Remover (8.6 inch and 9.5 inch LD Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch and 9.5 inch LD axles) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (8.6 inch and 9.5 inch LD axles) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10261 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128 (8.6 inch and 9.5 inch LD axles) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10262 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement (W/Rear Drum) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) ^ Tools Required J 8092 Universal Driver Handle-3/4 in - 10 - J 21128 Axle Pinion Oil Seal Installer - J 23690 Axle Shaft Bearing Installer - J 2619-01 Slide Hammer - J 44685 Rear Axle Seal and Bearing Remover Removal Procedure 1. Remove the axle shaft. 2. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (1) and the J 2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10263 3. Install the axle shaft seal using the J 21128. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10264 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal Replacement - Outer Rear Axle Shaft Seal Replacement - Outer Removal Procedure 1. Raise the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the axle shaft. 4. Remove the axle shaft seal. Installation Procedure 1. Install the axle shaft seal. 2. Install the axle shaft. 3. Install the tire and wheel assembly. Rear Axle Shaft Seal Replacement - Inner Rear Axle Shaft Seal Replacement - Inner ^ Tools Required J 33049 Camshaft Bearing Service Set - J 45177 Differential Seal Installer - Inner Removal Procedure 1. Raise the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the axle shafts. 4. Remove the differential assembly. 5. Install the smallest expanding driver (3) and the small driving washer (1) onto the expander assembly (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10265 6. Align the separation lines between the expanding driver and the expander assembly. 7. Assemble the expander assembly (2) onto the driver bar extension (1). 8. Assemble the drive bar extension onto the driver bar. 9. Insert the J 33049 into the axle tube and through the axle shaft seal. 10. While holding the expander assembly nut, turn the driving bar clockwise until the expanding driver is snug against the axle shaft seal. 11. Drive out the seal using the J 33049 and a hammer. Installation Procedure 1. Assemble the drive bar extension onto the drive bar of J 33049. 2. Insert the J 33049 into the opposite side axle shaft tube. 3. Install the J 45177 onto the J 33049. 4. Insert the axle shaft seal into the axle tube. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10266 5. Install the J 45177 (1) and the J 33049 (2) over the axle shaft seal. 6. Drive the axle shaft seal into the axle tube using the J 45177, the J 33049 and a hammer. 7. Install the differential assembly. 8. Install the axle shafts. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Rear Axle Shaft Seal and/or Bearing Replacement (W/Rear Disc) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) ^ Tools Required J 8092 Universal Driver Handle-3/4 in - 10 - J 21128 Axle Pinion Oil Seal Installer (8.6 inch and 9.5 inch LD Axles) - J 23690 Axle Shaft Bearing Installer (8.6 inch and 9.5 inch LD Axles) - J 2619-01 Slide Hammer - J 29709 Wheel Bearing Installer (9.5 inch Axle) - J 29712 Wheel Bearing Remover (9.5 inch Axle) - J 29713 Axle Seal Installer (9.5 inch Axle) - J 44685 Rear Axle Seal and Bearing Remover (8.6 inch and 9.5 inch LD Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch and 9.5 inch LD axles) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10267 1. Install the axle shaft bearing using the J 23690 (8.6 inch and 9.5 inch LD axles) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128 (8.6 inch and 9.5 inch LD axles) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. 9. Lower the vehicle. Rear Axle Shaft Seal and/or Bearing Replacement (W/Rear Drum) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) ^ Tools Required J 8092 Universal Driver Handle-3/4 in - 10 - J 21128 Axle Pinion Oil Seal Installer - J 23690 Axle Shaft Bearing Installer - J 2619-01 Slide Hammer - J 44685 Rear Axle Seal and Bearing Remover Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10268 1. Remove the axle shaft. 2. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (1) and the J 2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10269 5. Install the axle shaft. Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Removal Procedure 1. Remove the flange bolts. 2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 3. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal. 4. Remove the axle shaft from the tube. 5. Remove the gasket. 6. Clean the axle shaft flange and the outside face of the hub assembly. Installation Procedure 1. Install the gasket onto the axle shaft. 2. Install the gasket and the axle shaft into the axle tube. 1. Ensure the shaft splines mesh into the differential side gear. 2. Align the holes in the axle flange and the gasket with the holes in the hub. 3. Install the axle flange bolts. ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 Nm (115 ft. lbs.). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 Nm (148 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Inspect and add axle lubricant to the axle housing, if necessary. Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10270 Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. 8. Remove the adjusting nut. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10271 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. 14. Remove the retaining ring from the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10272 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10273 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). 8. Install the inner bearing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 10274 9. Install the new oil seal using the J 44420 (2) and the J 8092 (1). Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. Refer to Wheel Bearing Adjustment. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 10279 Wheel Bearing: Fluid Type Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 10280 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 10281 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 10282 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 10283 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle Wheel Bearing: Service and Repair Rear Drive Axle Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting, See: Maintenance/Vehicle Lifting/Service and Repair 2. Remove the tire and wheel assembly, See: Maintenance/Wheels and Tires/Service and Repair 3. Remove the brake caliper bracket. It is not necessary to remove the brake caliper from the bracket. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 4. Remove the axle shaft, See: Axle Shaft Assembly/Axle Shaft/Service and Repair 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10286 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10287 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10288 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). - Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Turn the wheel hub over and seat the outer bearing assembly against the retaining ring using the J 24426 (2) and the J 8092 (1). 7. Ensure that the outer bearing assembly rotates freely in the hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10289 8. Turn the wheel hub over and install the inner bearing cup. 9. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). 10. Install the inner bearing. 11. Install the new oil seal using the J 44420 (2) and the J 8092 (1). Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. 12. Install the rotor, if necessary, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair 13. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10290 14. Install the wheel hub to the axle housing. 15. Install the adjusting nut to the hub using the J 2222-C. 16. Adjust the wheel bearings. Refer to Wheel Bearing Adjustment, See: Adjustments 17. Install the axle shaft, See: Axle Shaft Assembly/Axle Shaft/Service and Repair 18. Install the brake caliper bracket, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 19. Install the tire and wheel assembly, See: Maintenance/Wheels and Tires/Service and Repair 20. Inspect and add axle lubricant to the axle housing, if necessary, See: Differential Assembly/Fluid - Differential/Service and Repair 21. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10291 Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10292 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10293 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10294 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10295 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10296 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10297 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10298 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10299 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10300 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10301 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10302 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 10303 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Install the wheel drive shaft retaining nut. Tighten the nut to ................................................................................................................................. ........................................... 250 Nm (184 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 10312 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 10313 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 10314 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 10315 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair > Page 10319 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair > Page 10320 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair > Page 10321 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair Propeller Shaft Center Support Bearing Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the propeller shaft. 3. Remove the center bearing by doing the following: 1. Stand the propeller shaft (2) on end in the press (1) with the center bearing (3) supported by the press bars (4). 2. Press the propeller shaft (2) down and off the center bearing (3). Installation Procedure 1. Install the center bearing (3) onto the propeller shaft (2) by pressing the center bearing onto the shaft using a press (1). 2. Install the propeller shaft. 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Mechanical Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Mechanical Specifications > Page 10330 Sealers, Adhesives, and Lubricants Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Locations > Front Propeller Shaft Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Locations > Front Propeller Shaft > Page 10333 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Locations > Front Propeller Shaft > Page 10334 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Locations > Page 10335 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The propeller shaft is a tube with universal joints at both ends which do not require periodic maintenance, that transmit power from the transfer case or transmission output shaft to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One Piece Propeller Shaft Description A 1 piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or transfer case. Two Piece Propeller Shaft Description There are 3 universal joints used on the two piece propeller shaft, A center bearing assembly is used to support the propeller shaft connection point, and help isolate the vehicle from vibration. Propeller Shaft Phasing Description The propeller shaft is designed and built with the yoke lugs (ears) in line with each other. This produces the smoothest running shaft possible. A propeller shaft designed with built in yoke lugs in line is known as in - phase. An out of phase propeller shaft often causes vibration. The propeller shaft generates vibration from speeding up and slowing down each time the universal joint goes around. The vibration is the same as a person snapping a rope and watching the wave reaction flow to the end. An in phase propeller shaft is similar to 2 persons snapping a rope at the same time and watching the waves meet and cancel each other out. A total cancellation of vibration produces a smooth flow of power in the drive line. All splined shaft slip yokes are keyed in order to ensure proper phasing. Universal Joint Description The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps are greased at the factory and no periodic maintenance is required. There are 2 universal joints used in a one piece propeller shaft and 3 used in two piece propeller shaft. The bearings and caps are pressed into the yokes and held in place with snap rings, except for 2 bearings on some models witch are strapped onto the pinion flange of the differential. Universal joints are designed to handle the effects of various loads and rear axle windup conditions during acceleration and braking. The universal joint operates efficiently and safely within the designed angle variations. when the design angles are exceeded, the operational life of the joint decreases. Center Bearing Description Center bearings support the driveline when using 2 or more propeller shafts. The center bearing is a ball bearing mounted in a rubber cushion that attaches to a frame crossmember. The manufacturer prelubricates and seals the bearing. The cushion allows vertical motion at the driveline and helps isolate the vehicle from vibration. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Propeller Shaft Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Propeller Shaft in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures/- Symptoms Propeller Shaft Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10338 Drive/Propeller Shaft: Symptom Related Diagnostic Procedures - Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Refer to Propeller Shaft Description and Operation. Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: ^ Leaks ^ Noises ^ Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft. For vibration related symptoms, refer to Diagnostic Starting Point - Vibration Diagnosis and Correction. Visual/Physical Inspection ^ Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Leak at Front Slip Yoke See: Leak at Front Slip Yoke ^ Universal Joint Noise See: Universal Joint Noise ^ Ping, Snap, or Click Noise See: Ping, Snap, or Click Noise ^ Knock or Clunk Noise See: Knock or Clunk Noise ^ Scraping Noise See: Scraping Noise ^ Squeak Noise See: Squeak Noise Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10339 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10340 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - One Piece Propeller Shaft Replacement - One Piece Removal Procedure 1. Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the propeller shaft to the rear axle pinion yoke. 3. Reference mark the propeller shaft to the transmission or transfer case. 4. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (3). 5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle pinion yoke. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transmission or transfer case. 7. Remove the propeller shaft from the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 10343 Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of grease. If the splines of the slip yoke does not have a sufficient coating of grease, lubricate the shaft with grease, GM P/N 12345879 or equivalent, RWD w/ Automatic Transmission Only. 2. Install the propeller shaft into the transmission or transfer case. Align the reference marks made during removal. 3. Install the propeller shaft (3) to the rear axle pinion yoke (4). Align the reference marks made during removal. 4. Install the yoke retainers (2) and bolts (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 10344 Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - Two Piece Propeller Shaft Replacement - Two Piece ^ Tools Required J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 3. Reference mark the front propeller shaft to the transmission or transfer case (slip yoke type) or to the transmission pinion yoke (universal joint type). 4. Remove the clamp (2) securing the boot (3) to the front propeller shaft stub shaft (4) and the rear propeller shaft slip yoke (1) by prying up the exposed end of the clamp (2) using a flat bladed tool (if applicable). 5. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 10345 6. Slide the rear propeller shaft forward in order to remove the propeller shaft from the rear axle pinion yoke. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 7. Slide the rear propeller shaft rearward in order to disconnect the rear propeller shaft from the front propeller shaft stub shaft. 8. Remove the rear propeller shaft from the vehicle. 9. Remove the boot from the front propeller shaft stub shaft (if applicable). 10. Remove the center bearing support nuts (1). 11. Remove the center bearing support (2). 12. Remove the front propeller shaft by sliding the front propeller shaft rearward from the transmission or the transfer case, w/o RPO MW3 or M74. 13. Remove the bolts and the yoke retainers from the transmission pinion yoke, w/ RPO MW3 or M74. 14. Remove the front propeller shaft by disconnecting the front propeller shaft from the transmission pinion yoke, w/ RPO MW3 or M74. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 10346 1. Install the front propeller shaft by sliding the front propeller shaft into the transmission or the transfer case, w/o RPO MW3 or M74. 2. Install the front propeller shaft to the transmission pinion yoke, w/ RPO MW3 or M74. 3. Install the yoke retainers and the bolts, w/ RPO MW3 or M74. Important: ^ Align the reference marks made during removal. ^ Tighten the bolts until snug. Do not torque the bolts at this time. 4. Install the center bearing support (2). 5. Install the center bearing support nuts. ^ Tighten the bearing support nuts to 40 Nm (30 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the yoke retainer bolts, w/ RPO MW3 or M74. ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 7. Inspect the splines of the front propeller shaft stub shaft for a sufficient coating of grease. If the splines of the stub shaft does not have a sufficient coating of grease, lubricate the shaft with chassis grease (GM P/N 12377985 or equivalent). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 10347 8. Install the boot (3) and two new clamps (2) onto the front propeller shaft stub shaft (4), if applicable. 9. Install the rear propeller shaft slip yoke onto the front propeller shaft stub shaft.Mate the missing tooth in the yoke with the bridged tooth on the splined shaft. 10. Install the rear propeller shaft onto the rear axle pinion yoke.Align the reference marks made during removal. 11. Install the yoke retainers (2) and the bolts (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 12. Using the J 43218, crimp the boot clamps until the dimensions shown are obtained. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 10348 Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - Front Propeller Shaft Replacement - Front ^ Tools Required J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Important: Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the following components: ^ The propeller shafts ^ The wheel drive shafts ^ The pinion flanges ^ The output shafts Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the rear propeller shaft boot clamp (4) by prying up the exposed end of the clamp with a flat-bladed tool. 4. Reference mark the relationship of the propeller shaft to the front axle pinion yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 10349 5. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). 6. Disconnect the propeller shaft (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. Important: Do not drop the bearing cap assemblies of the yoke end. 7. Disconnect the boot from the groove on the OD of the transfer case output shaft. 8. Remove the propeller shaft from the transfer case output shaft by sliding the propeller shaft forward. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the output shaft does not have a sufficient coating of lubricant, lubricate the shaft with grease, GM P/N 12345879 (Canadian P/N 10953511) or equivalent lubricant meeting GM Specification 9985830. 2. Install a new clamp onto the propeller shaft boot. 3. Install the propeller shaft splines into the transfer case output shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 10350 4. Install the propeller shaft (5) to the front axle pinion yoke (1). Align the reference marks made during removal. 5. Install the yoke retainers (7) and the bolts (6). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the boot onto the transfer case output shaft until the boot snaps into the groove on the output shaft. 7. Crimp the rear propeller shaft boot clamp using the J 43218 until the dimensions shown are obtained. 8. Install the transfer case shield, if equipped. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 10351 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring Universal Joint: Service and Repair Universal Joint Replacement - Nylon Injected Ring Universal Joint Replacement - Nylon Injected Ring ^ Tools Required J 9522-3 U Joint Bearing Separator - J 9522-5 U Joint Bearing Spacer Remover Disassembly Procedure 1. Support the propeller shaft in a line horizontal with the table of a press. Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 2. Mark the propeller shaft as to which end is the transmission end and which end goes to the rear axle. 3. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 inch) socket. 4. In order to shear the plastic retaining ring on the bearing cup, place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 5. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue to press the bearing cup out of the yoke. 6. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 7. Mark the orientation of the slip yoke to the tube for proper reassembly. 8. Remove the cross from the yoke. 9. Remove the remaining universal joint parts from the yoke. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 10. Inspect the retaining ring grooves for plastic. 11. Inspect the bearing cup bores in the yoke ears for burrs or imperfections. 12. Clean the remains of the sheared plastic bearing retainers from the grooves in the yoke. 13. The sheared plastic may prevent the bearing cups from pressing into place and thus prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 10356 2. Assemble 1 bearing cup part way into 1 side of the yoke. 3. Turn the yoke ear toward the bottom. 4. Assemble the cross into the yoke so the trunnion seats freely into the bearing cup. 5. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 6. Assemble the opposite bearing cup part way into the yoke ear. 7. Ensure that the trunnions start straight and true into both bearing cups. 8. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for a free unbinding movement of the trunnions in the bearing cups. 9. Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke. Important: If there seems to be a hangup or binding, stop pressing, and inspect the needle bearings for misalignment in the bearing cup. 10. Assemble the bearing retainer in the retainer groove. 11. Continue pressing until you can snap both retainers into place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 10357 12. If seating the retainer is difficult, spring the yoke slightly with a firm blow from a dead blow hammer. 13. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so the snap ring seats in the bearing cup groove. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 10358 Universal Joint: Service and Repair Universal Joint Replacement - External Snap Ring Universal Joint Replacement - External Snap Ring ^ Tools Required J 9522-3 U-Joint Bearing Separator - J 9522-5 U-Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft in order to show which end connects to the transmission and which end goes to the rear axle. 3. Disassemble the snap rings by pinching the ends together with a pair of pliers. 4. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 inch) hex head socket or a 27 mm (1-1/16 inch) socket. 6. Place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 7. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 8. Rotate the propeller shaft . Press the opposite bearing cup out of the yoke. 9. Mark the orientation of the slip yoke to the tube for proper reassembly. 10. Remove the cross from the yoke. 11. Remove the remaining universal joint parts from the yoke. 12. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 14. Inspect the bearing cup bores for burrs or imperfections. 15. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 10359 2. Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the bottom. 3. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. 4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 5. Install the opposite bearing cup part way into the yoke ear. 6. Ensure that the trunnions start straight and true into both bearing cups. 7. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. 8. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 9. Assemble the bearing retainer in the retainer groove. 10. Continue pressing until both retainers can be snapped into place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 10360 11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead blow hammer. 12. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > 4L60-E/4L65-E Flex Plate: Specifications 4L60-E/4L65-E Flywheel to Torque Converter Bolt ......................................................................................................................................................... 63 Nm (46 ft. lbs.) Flexplate. Install the flexplate bolts. 5.3L ^ Tighten the bolts to .............................................................................................................................. ................................... 100 Nm (74 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > 4L60-E/4L65-E > Page 10365 Flex Plate: Specifications 4L80-E/4L85-E Flywheel Housing Cover to Transmission ............................................................................................................................................... 7 Nm (62 inch lbs.) Flywheel to Converter .................................................................................................... .......................................................................... 43 Nm (32 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > 4L60-E/4L65-E > Page 10366 Flex Plate: Specifications Allison Torque Converter to Flywheel Bolts ......................................................................................................................................................... 60 Nm (44 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Tighten the bolts a first pass in sequence ................................................................................................................................................. 20 Nm (15 ft. lbs.) Tighten the bolts a second pass in sequence ............................................................................................................................................ 50 Nm (37 ft. lbs.) Tighten the bolts a final pass in sequence .............................................................................................................................................. 100 Nm (74 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 10370 Flywheel: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the transmission. Important: Note the position and direction of the engine flywheel before removal. 2. Remove the flywheel bolts. 3. Remove the flywheel. 4. Install two M11 x 1.5 mm bolts (1) to the threaded holes of the spacer, if applicable. 5. Rotate the bolts clockwise to remove the spacer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 10371 6. Remove the spacer from the rear of the crankshaft, if applicable. Installation Procedure Important: ^ The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange or spacer, if applicable, but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. ^ Certain applications (6.0L) require a spacer and longer bolts for proper flywheel position. 1. Install the spacer, if applicable, onto the rear of the crankshaft. 2. Install the flywheel and bolts to the crankshaft. Important: Longer flywheel bolts must be used on applications using a flywheel spacer. 3. Apply threadlock GM P/N 12345382, (Canadian P/N 10953489) or equivalent to the threads of the flywheel bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the flywheel bolts. 1. Tighten the bolts a first pass in sequence to 20 Nm (15 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 10372 2. Tighten the bolts a second pass in sequence to 50 Nm (37 ft. lbs.). 3. Tighten the bolts a final pass in sequence to 100 Nm (74 ft. lbs.). 5. Install the transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation SHIFT INDICATOR The instrument panel cluster (IPC) illuminates the shift indicator when the powertrain control module (PCM) determines that the vehicle should be shifted to the next higher gear. The IPC receives a class 2 message from the PCM requesting illumination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Differential Fluid - M/T: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Fluid - M/T: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid NV3500 ................................................................................................................ ............................................................................................. 2.0L (2.2 Qt) NV4500 ............................ .............................................................................................................................................................. ................... 3.7L (4.0 Qt) 6 Speed (ZF) (RPO ML6) ........................................................................... ...................................................................................................... 6.0L (6.3 Qt) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 10397 Fluid - M/T: Fluid Type Specifications Manual Transmission 5-Speed with Low Gear - RPO MW3 GM Goodwrench Synthetic Manual Transmission Fluid (GM Part No. U.S. 12346190, in Canada 10953477) or equivalent SAE 75W-85 GL-4 gear oil. 5-Speed without Low Gear - RPO MG5 Synchromesh Transmission Fluid (GM Part No. U.S. 12345349, in Canada 10953465). 6-Speed Castrol TransSynd Synthetic Transmission Fluid approved to Allison Transmission specification TES-295 (GM Part No. U.S. 12378515, in Canada 88900701). RPO MG5 - Transmission Manual 5-Speed, Getrag, 84mm, 4.00 1st, O/D RPO MW3 Transmission Manual 5-Speed, NVG, 109mm, 5.61 1st, O/D Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 Fluid - M/T: Service and Repair NV 3500 Transmission Fluid Replacement ^ Tools Required J 36511 Oil Fill/Drain Plug Hex Bit (17 MM) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 10400 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. 2. Notice: Refer to Fastener Notice in Service Precautions. Using J 36511 install the oil drain plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 10401 5. Using J 36511 install the oil fill plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 10402 Fluid - M/T: Service and Repair NV 4500 Control Lever and/or Boot Replacement Removal Procedure 1. Important: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. Remove the control lever. 2. Remove the control lever boot retainer plastic retainers, if necessary. 3. Remove the control lever boot retainer, if necessary. 4. Remove the control lever boot screws, if necessary. 5. Remove the control lever boot, if necessary. 6. Remove the control lever insulator, if necessary. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 10403 1. Install the control lever insulator, if removed. 2. Install the control lever boot to the control lever, if removed. 3. Install the control lever. 4. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 5. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. 6. Notice: Refer to Fastener Notice in Service Precautions. Hold the control lever and tighten the shift lever assembly nut against the control lever. ^ Tighten the nut to 37 Nm (27 ft. lbs.). 7. Seat the control lever boot to the floor. 8. Install the control lever boot screws, if removed. ^ Tighten the screws to 1.6 Nm (14 inch lbs.). 9. Install the control lever boot retainer, if removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 10404 Fluid - M/T: Service and Repair ZF S6-650 Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing and plugs. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the oil drain and fill plugs. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 3. Fill the transmission to just below the bottom of the fill plug hole. 4. Install the oil fill plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 Seals and Gaskets: Service and Repair NV 3500 Transmission Housing Oil Seal Replacement - Front Transmission Housing Oil Seal Replacement - Front Removal Procedure 1. Remove the transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. 4. Remove the input shaft bearing retainer bolts.Remove the input shaft bearing retainer.Screw 2 of the removed bolts into the threaded holes in the retainer in order to remove the retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 10409 5. Using a hammer and a punch, remove the transmission housing front oil seal from the input shaft bearing retainer. 6. Remove the old gasket material from the input shaft bearing retainer. Installation Procedure Important: Inspect the input shaft bearing retainer for any nicks or cracks that may result in a leak. Replace as necessary. 1. Position a NEW oil seal in the input shaft bearing retainer. 2. Using a suitable tool, install the oil seal. 3. Apply RTV sealer GM P/N 12345739 (Canadian P/N 10953472), or equivalent to the inside edge of the bearing retainer mating surface. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 10410 4. Position the input shaft bearing retainer.Align the bearing retainer oil drain hole with the drain hole in the transmission housing. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the input shaft bearing retainer bolts. ^ Tighten the bolts to 14 Nm (10 ft. lbs.). 6. Install the clutch actuator cylinder and the bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.) 7. Install the transmission. 8. Lower the vehicle. Transmission Housing Oil Seal Replacement - Rear Transmission Housing Oil Seal Replacement - Rear (4WD) ^ Tools Required J 36825 Output Shaft Oil Seal Remover - J 23907 Slide Hammer - J 36502-2A Output Shaft Oil Seal Protector - J 36502 Extension Housing Seal Installer Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 10411 1. Remove transfer case. 2. Using J 36825 and J 23907 remove the output shaft seal. Installation Procedure 1. Position the J 36502-2A over the output shaft. 2. Using J 36502 install the NEW output shaft seal. 3. Remove the J 36502-2A from the output shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 10412 4. Fill the space between the seal lips with grease GM P/N 1052497 or equivalent. 5. Install transfer case. 6. Check the transmission fluid level. Add as necessary. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 10413 Seals and Gaskets: Service and Repair NV 4500 Transmission Housing Oil Seal Replacement - Front Removal Procedure ^ Tools Required J 38801 Input Shaft Seal Installer 1. Remove the transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. 4. Remove the input shaft bearing retainer bolts.Remove the input shaft bearing retainer.Screw 2 of the removed bolts into the threaded holes in the retainer in order to remove the retainer. 5. Using a hammer and a punch, remove the transmission housing front oil seal from the input shaft bearing retainer. 6. Remove the old gasket material from the input shaft bearing retainer. Installation Procedure Important: Inspect the input shaft bearing retainer for any nicks or cracks that may result in a leak. Replace as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 10414 1. Position a NEW oil seal in the input shaft bearing retainer. 2. Using J 38801, install the oil seal. 3. Apply a thin bead of RTV sealer GM P/N 12345739 (Canadian P/N 10953472), or equivalent to the input shaft bearing retainer mating surface. 4. Position the input shaft bearing retainer. 5. Align the bearing retainer oil drain hole at the top dead center position. 6. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the input shaft bearing retainer bolts. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the input shaft bearing retainer bolts. ^ Tighten the bolts to 22 Nm (16 inch lbs.). 8. Install the clutch actuator cylinder and bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 9. Install the transmission. 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 10415 Seals and Gaskets: Service and Repair ZF S6-650 Transmission Input Shaft Seal Replacement Transmission Input Shaft Seal Replacement ^ Tools Required J 23907 Slide Hammer - J 44748 Seal Remover - J 44731 Input Shaft Oil Seal Installer Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Remove the rear propeller shaft. 3. Remove the transmission. Important: The clutch actuator hose can remain connected to the clutch actuator. Disconnecting the hose from the clutch actuator will allow the hydraulic fluid to drain from the hydraulic system. 4. Remove the clutch actuator cylinder bolts. Do not disconnect the hose from the actuator. 5. Remove the clutch actuator cylinder. 6. Remove the front oil seal using J 23907 (2) and J 44748 (1). Installation Procedure 1. Position the NEW seal in the front case with the part number facing out. 2. Using J 44731 install the input shaft seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 10416 3. Notice: Refer to Fastener Notice in Service Precautions. Position the clutch actuator cylinder. 4. Install the clutch actuator cylinder bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 5. Install the transmission. 6. Install the rear propeller shaft. 7. Check the transmission fluid level. Add if necessary. 8. Lower the vehicle. Transmission Output Shaft Seal Replacement Transmission Output Shaft Seal Replacement ^ Tools Required J 6125-1B Slide Hammer - J 44732 Output Shaft Oil Seal Installer - J 23129 Universal Seal Remover - J 8614-01 Pinion Flange Holder Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Remove the rear propeller shaft. 3. Using the J 8614-01 to hold the transmission yoke, remove and discard the yoke nut. 4. Remove the yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 10417 5. Using J 6125-1B (1) and J 23129 (2), remove the rear oil seal. Installation Procedure Important: The J 44732 will set the oil seal to the proper depth. Failure to use the J 44732 will cause improper installation of the oil seal. 1. Using J 44732 install the rear oil seal. 2. Install the yoke. 3. Use the J 8614-01 in order to hold the yoke. Notice: Refer to Fastener Notice in Service Precautions. 4. Install a NEW yoke nut. ^ Tighten the nut to 330 Nm (244 ft. lbs.). 5. Install the rear propeller shaft. 6. Check the transmission fluid level. Add if necessary. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 Transmission Speed Sensor: Locations NV 3500 Manual Transmission Component Views Manual Transmission - NV 3500 Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 10423 Transmission Speed Sensor: Locations NV 4500 Manual Transmission Component Views Manual Transmission - NV 4500 Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 10424 Transmission Speed Sensor: Locations ZF S6-650 Manual Transmission Component Views Manual Transmission - ZF S6-650 Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 10427 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 10428 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10431 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10432 Transmission Speed Sensor: Service and Repair NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10433 3. Connect the VSS electrical connector (3).Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10434 Transmission Speed Sensor: Service and Repair ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. If equipped with the 6.6L engine , disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10435 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine , connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > NV 3500 Shifter M/T: Service and Repair NV 3500 Shift Lever Assembly Replacement Removal Procedure Important: ^ Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever from the transmission. The transmission must remain in this state when the shift lever is removed. ^ Do not disassemble the transmission shift lever. Internal parts for this shift lever are not available. Opening the shift lever voids the warranty. ^ When removing the shift lever from the transmission, use the exposed bolts on the base of the lever. 1. Remove the control lever and boot. 2. Remove the boot. 3. Remove the shift lever bolts. 4. Remove the shift lever and seal. 5. Remove the shift lever insulator. Installation Procedure 1. Install a NEW shift lever insulator. 2. Install the shift lever seal and lever. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the shift lever bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 4. Install the boot. 5. Install the control lever and boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > NV 3500 > Page 10440 Shifter M/T: Service and Repair NV 4500 Shift Lever Assembly Replacement Removal Procedure Important: ^ Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever from the transmission. The transmission must remain in this state when the shift lever is removed. ^ Do not disassemble the transmission shift lever. Internal parts for this shift lever are not available. Opening the shift housing lever voids the warranty. ^ When removing the shift lever from the transmission, use the exposed bolts on the base of the lever. 1. Remove the control lever and boot. 2. Remove the transmission support. 3. Lower the transmission slightly to access to insulator. 4. Cut one side of the insulator in order to remove it. Remove the insulator. 5. Remove the shift lever and seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > NV 3500 > Page 10441 1. Install the shift lever seal and lever. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shift lever bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 3. Install the insulator. 4. Raise the transmission. 5. Install the transmission support. 6. Install the control lever and boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > NV 3500 > Page 10442 Shifter M/T: Service and Repair ZF S6-650 Shift Lever Assembly Replacement Removal Procedure Important: ^ Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever assembly from the transmission. The transmission must remain in this state when the shift lever assembly is removed. ^ When removing the shift lever assembly from the transmission, use the exposed bolts on the base of the shift lever assembly. 1. Remove the control lever and boot. 2. With a flat-bladed tool, pull back the insulator between the body and transmission to access the shift tower bolts. 3. Remove the boot. 4. Remove the shift lever bolts. 5. Remove the shift lever and seal. 6. Remove the shift lever insulator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > NV 3500 > Page 10443 1. Install a NEW shift lever insulator, if required. 2. Apply gasket maker GM P/N 12378517 or equivalent to the surface of the control lever assembly. 3. Push the shift lever assembly back through the insulator, position and turn the shift lever assembly back into place. 4. With a flat tool pull back the insulator between the body and transmission to install the shift lever assembly bolts. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the shift lever assembly bolts. ^ Tighten the bolts to 23 Nm (17 ft. lbs.). 6. Install the control lever and boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > NV 3500 Shift Boot: Service and Repair NV 3500 Control Lever and/or Boot Replacement Removal Procedure 1. Important: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. Remove the control lever. 2. Remove the control lever boot retainer plastic retainers, if necessary. 3. Remove the control lever boot retainer, if necessary. 4. Remove the control lever boot screws, if necessary. 5. Remove the control lever boot, if necessary. 6. Remove the control lever insulator, if necessary. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > NV 3500 > Page 10449 1. Install the control lever insulator, if removed. 2. Install the control lever boot to the control lever, if removed. 3. Install the control lever. 4. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 4. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. 5. Notice: Refer to Fastener Notice in Service Precautions. Hold the control lever and tighten the shift lever assembly nut against the control lever. ^ Tighten the nut to 37 Nm (27 inch lbs.). 5. Seat the control lever boot to the floor. 6. Install the control lever boot screws, if removed. ^ Tighten the screws to 1.6 Nm (14 inch lbs.). 7. Install the control lever boot retainer, if removed. 8. Install the control lever boot retainer plastic retainers, if removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > NV 3500 > Page 10450 Shift Boot: Service and Repair ZF S6-650 Control Lever and/or Boot Replacement Removal Procedure 1. Remove the control lever. Important: Loosen DO NOT remove the shift lever assembly adjustment nut if replacing the control lever. 2. Remove the control lever boot retainer plastic retainers, if necessary. 3. Remove the control lever boot retainer, if necessary. 4. Remove the control lever boot screws, if necessary. 5. Remove the control lever boot, if necessary. 6. Remove the control lever insulator, if necessary. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > NV 3500 > Page 10451 1. Install the control lever insulator, if removed. 2. Install the control lever boot to the control lever, if removed. 3. Install the control lever. 4. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 5. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. Notice: Refer to Fastener Notice in Service Precautions. 6. Hold the control lever and tighten the shift lever assembly nut against the control lever. ^ Tighten the nut to 37 Nm (27 ft. lbs.). 7. Seat the control lever boot to the floor. 8. Install the control lever boot screws, if removed. ^ Tighten the screws to 1.6 Nm (14 inch lbs.). 9. Install the control lever boot retainer, if removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > NV 3500 Transmission Mount: Service and Repair NV 3500 Transmission Mount Replacement - Rear Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Remove the transmission mount to crossmember nut. 3. Remove the transmission mount to transmission bolts. 4. Raise the transmission just enough in order to permit removal of the mount using a suitable transmission jack. 5. Remove the transmission mount. Installation Procedure 1. Position the transmission mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount to transmission bolts. ^ Tighten the transmission mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission and remove the transmission jack. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > NV 3500 > Page 10456 4. Install the transmission mount to crossmember nut. ^ Tighten the transmission mount to crossmember nut to 40 Nm (30 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > NV 3500 > Page 10457 Transmission Mount: Service and Repair NV 4500 Transmission Mount Replacement - Rear Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Remove the transmission mount to crossmember nut. 3. Remove the transmission mount to transmission bolts. 4. Raise the transmission just enough, in order to permit removal of the mount using a suitable transmission jack. 5. Remove the transmission mount. Installation Procedure 1. Position the transmission mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount to transmission bolts. ^ Tighten the transmission mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission and remove the transmission jack. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > NV 3500 > Page 10458 4. Install the transmission mount to crossmember nut. ^ Tighten the transmission mount to crossmember nut to 40 Nm (30 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > NV 3500 > Page 10459 Transmission Mount: Service and Repair ZF S6-650 Transmission Mount Replacement - Rear Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Remove the transmission mount to crossmember nuts. 3. Remove the transmission mount bolts to the transmission. 4. Raise the transmission using a suitable transmission jack, just enough in order to permit the removal of the mount. 5. Remove the transmission mount. Installation Procedure 1. Install the rear transmission mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount bolts. ^ Tighten the transmission mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission. 4. Install the transmission mount to crossmember nuts. ^ Tighten the transmission mount to crossmember nuts to 54 Nm (40 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 Transmission Speed Sensor: Locations NV 3500 Manual Transmission Component Views Manual Transmission - NV 3500 Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 10464 Transmission Speed Sensor: Locations NV 4500 Manual Transmission Component Views Manual Transmission - NV 4500 Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 10465 Transmission Speed Sensor: Locations ZF S6-650 Manual Transmission Component Views Manual Transmission - ZF S6-650 Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 10468 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 10469 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10472 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10473 Transmission Speed Sensor: Service and Repair NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10474 3. Connect the VSS electrical connector (3).Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10475 Transmission Speed Sensor: Service and Repair ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. If equipped with the 6.6L engine , disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10476 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine , connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Locations Power Take-Off: Locations Power Take Off (PTO) Relay Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Locations > Page 10480 C104, C114, C150, C151, C153, C154, And PTO Relay Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions Power Take-Off: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10483 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10484 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10485 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10486 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10487 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10488 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10489 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10490 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10491 Power Take-Off: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10492 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10493 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10494 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10495 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10496 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10497 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10498 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10499 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10500 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10501 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10502 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10503 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10504 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10505 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10506 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10507 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10508 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10509 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10510 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10511 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10512 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10513 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10514 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10515 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10516 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10517 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10518 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10519 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10520 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10521 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10522 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10523 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10524 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10525 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10526 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10527 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10528 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10529 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10530 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10531 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10532 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10533 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10534 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10535 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10536 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10537 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10538 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10539 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10540 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10541 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10542 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10543 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10544 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10545 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10546 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10547 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10548 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10549 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10550 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10551 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10552 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10553 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10554 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10555 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10556 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10557 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10558 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10559 Power Take-Off: Connector Views Power Take Off (PTO) Relay Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 10560 Power Take Off (PTO) Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Page 10561 Power Take-Off: Description and Operation POWER TAKE-OFF (PTO) DESCRIPTION AND OPERATION The PTO is an Upfitter integrated system that allows the user to create an auxiliary power source that will drive either a hydraulic pump or a generator. When the operator requests PTO the PTO switch will be turned ON and the engine RPM will go to a default standby speed. The operator will then press and release the PTO switch to SET and the PTO solenoid will engage. Turning the PTO switch to OFF or pressing the brake pedal will turn the PTO off. The PTO system is integrated with the Cruise Control system and Computers and Control Systems. The PTO system utilizes the following parts: - PTO Switch - Cruise Control Multi-Function Switch - PTO Relay - PTO Solenoid - PCM with 8.1L gasoline only - ECM with 6.6L diesel only - TAC Module with 8.1L gasoline only - TAC Motor with 8.1L gasoline only Voltage will be supplied at all times through the Fog Lamp fuse to the secondary side of the PTO Relay. When the operator turns the ignition switch to RUN, voltage will be supplied through the Cruise fuse to the open PTO switch. When the PTO switch is turned ON voltage will be present through the primary side of the PTO Relay and at the PCM. If the PCM sees all of the requirements for PTO engagement the PCM will send a Class 2 signal to the TAC Module. The TAC Module will use the TAC Motor to increase the engine RPM to the standby speed. When the PTO switch is turned to the SET position and released the PCM will ground the primary side of the PTO Relay. Current will flow through the coil in the PTO Relay and close the normally open contacts. This will allow current to flow to the PTO Solenoid and eventually to ground. In the event that any of the PTO requirements are no longer met then the PCM or TAC will return the engine RPM to idle and turn the PTO Solenoid off. Modes of Operation PTO - Preset Mode (Factory Default Setting) The PTO preset mode is used for stationary applications. PTO will remain engaged while mobile in the preset mode however PTO Preset 1 and PTO Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Page 10562 Preset 2 speed controls will be inoperative. The engine RPM will also return to normal. This mode provides a default standby speed of 800 or 850 RPM depending on the engine and transmission combination. This mode also provides 2 default PTO control speeds: PTO Preset 1 of 1250 RPM and PTO Preset 2 of 1700 RPM. Please note that the standby speed is not to be used as a PTO control speed. Vehicles not equipped with cruise control will not have the resume speed capability. PTO - Variable Mode The PTO speed control mode is used for both stationary and mobile applications. This mode allows PTO to be controlled in a fashion similar to cruise control. The operator is able to hold an engine RPM between 800 and 2200 with the SET switch on the cruise stock or the PTO switch. The operator can "tap up" to increase engine speed in 100 RPM increments with the RESUME switch. The operator may also "tap down" to decrease engine speed with either SET switch on the cruise control multifunction switch or the PTO switch. Vehicles not equipped with cruise control will not have the "tap up" capability. PTO Components PTO Switch The PTO Switch is mounted in the center of the Instrument Panel. The PTO Switch has three positions: OFF, ON and SET. When the PTO switch is in ON voltage will be present on the PTO On Switch Signal circuit at the relay and the PCM. When the switch is held to the SET position, voltage will be present on the PTO Engage Signal circuit at the PCM. The PTO indicator light is integral with the switch and will illuminate when the switch is turned ON. The presence of the indicator being on does not mean that the PTO Solenoid is engaged. The Cruise Control Multi-Function Switch may be used in conjunction with the PTO Switch. Illumination of the switch is provided through the dimming circuit and controlled in part by internal switch logic. Cruise Control Multi-Function Switch The operation of the PTO system may be through the function control switches located on the multifunction turn signal lever. The cruise control function control switches includes the ON/OFF, SET/COAST, and R/A. The switch assembly provides driver control of the PTO as well as the cruise control system. The SET/COAST and R/A switches may be used to increase and decrease engine RPM in increments of 100 RPM. See the chart below for recommended speeds. PTO Relay The PTO Relay is located on the side of the underhood fuse block. The secondary side of the relay is supplied with voltage at all times through the Fog Lamp fuse. The PTO switch controls the voltage to the primary side of the PTO relay while the PCM controls the ground. PTO Solenoid The solenoid is an upfitter supplied part and is replaceable on most PTOs. The PTO solenoid is used on clutch activated PTOs. The PTO relay supplies the solenoid with voltage when the relay is energized. PCM The powertrain control module (PCM) is the control center of the PTO system. Applications with a 6.6L diesel use an ECM. The PCM monitors numerous engine and vehicle functions. To engage the PTO, the PCM must see the following conditions: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Page 10563 - PTO switch is ON - Engine must be running - Transmission must be in PARK or NEUTRAL - Park Brake must be set for manual transmission only - Vehicle speed must be zero in Preset Mode only - Brake or Clutch must not be depressed The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance. The PCM also performs a diagnostic test on the Electronic Throttle Control system. TAC Module The TAC module is the control center for the electronic throttle system. The TAC module and the PCM communicate through a dedicated redundant serial data circuit. The TAC module and the PCM monitor the commanded throttle position and compare the commanded position to the actual throttle position. This is accomplished by monitoring the APP and the throttle position (TP) sensor. These 2 values must be within a calibrated value of each other or a DTC may be set. The TAC module also monitors each individual circuit of the TP sensor and the APP to verify proper operation. The TAC module commands the TAC motor to increase or decrease the engine RPM. TAC Motor The TAC motor is part of the throttle body and controls the positions of the throttle. The motor is bi-directional and is controlled by the TAC module. The TAC motor increases or decreases the engine RPM. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Power Take-Off: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT IMPORTANT: The following steps must be completed before using the symptom tables: 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, before using the Symptom Tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data link. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system Description and Operation in order to familiarize yourself with the system functions. Refer to Power Take-Off (PTO) Description and Operation. Visual/Physical Inspection Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. - Inspect the transmission for the proper transmission fluid level. - Inspect the hydraulic reservoir for the proper hydraulic fluid level. - Inspect the upfitter connections at the transmission. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Power Take-Off Does Not Engage - Engine RPM Does Not Increase With Power Take-Off Engaged - Power Take-Off Indicator Inoperative Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10566 Power Take-Off: Symptom Related Diagnostic Procedures - Symptoms - Power Take-Off (PTO) SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, before using the Symptom Tables in order to verify that all of the following are true: There are no powertrain control module (PCM) or throttle actuator control (TAC) module DTCs set. - The PCM and TAC module can communicate to each other via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Power Take-Off (PTO) Description and Operation. Visual/Physical Inspection Inspect the upfitter connections of the PTO system. - Inspect the easily accessible, or the visible system components for obvious damage or conditions which could cause the symptom. - Inspect the transmission and the hydraulic pump for the proper fluid level. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Power Take-Off (PTO) Does Not Engage - Engine RPM Does Not Increase with Power Take-Off Engaged - Power Take-Off (PTO) Indicator Inoperative Engine RPM Does Not Increase with Power Take-Off Engaged ENGINE RPM DOES NOT INCREASE WITH POWER TAKE-OFF ENGAGED CIRCUIT DESCRIPTION When the power take-off (PTO) switch is turned to the ON position and all PTO engage conditions are met, the engine RPM should increase to the standby speed. When the powertrain control module (PCM) receives the signal from the PTO switch the PCM will send a signal to the throttle actuator control module (TAC). The TAC module controls the TAC motor which changes the position of the throttle. Communications between the two modules is monitored and checked for accuracy by the PCM. DTCs may be recorded in the event of the failure. The 6.6L diesel engine does not have a TAC system and the engine RPM is strictly controlled by the engine control module (ECM) and the Fuel Injection Control Module. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10567 Steps 1-13 The numbers below refer to the step numbers on the diagnostic table. 3. This step checks for other system DTCs that may affect the PTO. 6. This step tests the PCM for the PTO Enable signal. 7. This step tests the communication between the PCM and the TAC module. 8. This step tests the PTO On Switch Signal circuit. 9. This step tests the PTO On Switch-Signal circuit for an open, high resistance or short to ground. 10. This step tests the Serial Data circuits for an open, high resistance or short to ground. Power Take-Off (PTO) Does Not Engage Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10568 POWER TAKE-OFF (PTO) DOES NOT ENGAGE CIRCUIT DESCRIPTION This symptom table aids in the diagnosis of a failed power take-off (PTO) solenoid engagement. This diagnostic does not expose a mechanical condition with the PTO itself. Voltage is supplied at all times through the cruise fuse to the secondary side of the relay. When the relay is energized, the contacts close and current is allowed to flow to the PTO solenoid. The solenoid has its own external ground. When the ignition switch is in the RUN position, voltage is present at the PTO switch. When the PTO switch is in the ON position, voltage is present at the coil of the relay and at the PCM. If the PCM sees all of the conditions necessary to engage the solenoid, the PCM grounds the primary circuit of the relay. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10569 Steps 1-13 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10570 Steps 14-19 The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for an open fog lamp fuse. 3. This step tests for open cruise fuse. 4. This step tests the battery positive circuit for battery voltage. 5. This step tests the battery positive circuit for an open. 6. This step tests the PTO relay output circuit for an open. 7. This step tests the PTO ON signal circuit for battery voltage. 8. This step tests the PTO ON signal circuit for an open. 9. This step tests the cruise control set/coast switch signal circuit for battery voltage. 10. This step tests the PTO status circuit for an open. 11. This step tests the PTO switch and PTO unit ground circuits for an open. 12. This step tests the battery positive and PTO relay output circuits for a short to ground. 13. This step tests the ignition 3 circuit for a short to ground. 14. This step tests the cruise control ON switch signal, cruise control set/coast signal, PTO status, and PTO ON signal circuits for a short to ground. 15. This step tests the control side of the PTO relay for proper operation. Power Take-Off (PTO) Indicator Inoperative POWER TAKE-OFF (PTO) INDICATOR INOPERATIVE CIRCUIT DESCRIPTION This symptom chart will aid in diagnosing a failed power take-off (PTO) indicator. This diagnostic assumes that the PTO solenoid is functional and only the indicator is failing to come on. When the ignition switch is in RUN, voltage should be present on the Ignition 3 Voltage circuit. When the PTO switch is turned to ON, the LED will illuminate. The indicator has its own ground circuit. The LED and PTO solenoid have different ground circuits. Therefore, the LED may be illuminated when the PTO solenoid is disengaged. TEST DESCRIPTION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10571 Steps 1-8 The number below refers to the step number on the diagnostic table. 5. This step tests the ground circuit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Page 10572 Power Take-Off: Service and Repair POWER TAKE-OFF (PTO) SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P cluster bezel. 2. Pull out the switch housing from the I/P. 3. Disconnect the wire connector to the PTO switch. 4. Remove the PTO switch from the switch housing. INSTALLATION PROCEDURE 1. Install the PTO switch to the housing 2. Connect the wire connector to the switch. 3. Install the switch housing to the I/P till it clicks into place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Page 10573 4. Install the I/P cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls Shared Diagnostic Trouble Codes Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 10585 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 10588 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 Control Module: Diagrams NVG 246-NP8 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10591 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10592 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10593 Control Module: Diagrams NVG 263-NP1 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10594 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10595 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10598 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10599 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10600 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Automatic Transmission Shift Lock Control Component Views Lower Steering Column Components Lower Steering Column Components 1 - A/T Shift Lock Control Actuator 2 - Steering Column Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 10610 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Fluid Pressure Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 10613 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 10614 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 10615 Fluid Pressure Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 10618 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10619 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10620 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10621 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Remove the remaining valve body bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10622 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10623 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Notice: Refer to Fastener Notice in Service Precautions. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10624 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10625 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Do not install the transmission fluid indicator stop bracket and bolt at this time.Install but do not tighten the valve body bolts which retain only the valve body directly.Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10626 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10627 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10628 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E > Page 10633 Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 10636 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 10637 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 10638 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 10643 Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 10646 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 10649 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 10650 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 10651 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 10652 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 10653 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Speed Sensor: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 10658 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 10659 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 10660 Transmission Speed Sensor: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E Transmission Speed Sensor: Diagrams 4L80-E/4L85-E Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 10663 Automatic Transmission Output Shaft Speed (AT OSS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 10664 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Speed Sensor: Service and Repair 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 10667 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 10668 Transmission Speed Sensor: Service and Repair 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 10669 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 10670 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 10671 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E > Page 10676 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Temperature Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 10679 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 10680 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 10681 Transmission Temperature Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 10682 Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 Transmission Speed Sensor: Locations NV 3500 Manual Transmission Component Views Manual Transmission - NV 3500 Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 10688 Transmission Speed Sensor: Locations NV 4500 Manual Transmission Component Views Manual Transmission - NV 4500 Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 10689 Transmission Speed Sensor: Locations ZF S6-650 Manual Transmission Component Views Manual Transmission - ZF S6-650 Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 10692 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 10693 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10696 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10697 Transmission Speed Sensor: Service and Repair NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10698 3. Connect the VSS electrical connector (3).Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10699 Transmission Speed Sensor: Service and Repair ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. If equipped with the 6.6L engine , disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 10700 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine , connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 Four Wheel Drive Selector Switch: Locations NVG 246-NP8 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 > Page 10706 Four Wheel Drive Selector Switch: Locations NVG 263-NP1 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 Four Wheel Drive Selector Switch: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10709 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10710 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10711 Four Wheel Drive Selector Switch: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10712 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 10713 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 10714 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Gear Sensor/Switch: Service and Repair NVG 246-NP8 Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to Neutral prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench. 3. Remove and discard 2 screws (2) from the motor cover. 4. Remove and discard 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10719 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat-tipped screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10720 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler gear are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10721 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10722 Gear Sensor/Switch: Service and Repair NVG 261-NP2 Transfer Case Gear Indicator Switch Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the gear indicator switch electrical connector (2). 3. Remove the gear indicator switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the gear indicator switch. ^ Tighten the switch to 27 Nm (20 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10723 2. Connect the gear indicator switch electrical connector (2). 3. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10724 Gear Sensor/Switch: Service and Repair NVG 263-NP1 Encoder Motor Sensor Replacement Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10725 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10726 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10727 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Transfer Case Shift Control Switch Replacement Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 10736 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 10742 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 10754 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10757 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10758 Speed Sensor: Service and Repair NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10759 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10760 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10761 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10762 Speed Sensor: Service and Repair NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10763 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10764 Speed Sensor: Service and Repair NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10765 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 Transfer Case Actuator: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 10772 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 10773 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 10774 Transfer Case Actuator: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 10775 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 Transfer Case Actuator: Service and Repair NVG 246-NP8 Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield. 2. Remove the front propeller shaft. 3. Disconnect the transfer case switch electrical connector (2). 4. Disconnect the encoder motor electrical connector (7). 5. Remove the encoder motor bolts. 6. Remove the encoder motor. 7. Remove the actuator insulator gasket. 8. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the transfer case at the shift shaft, using a crescent wrench if necessary. ^ When installing the encoder motor, ensure that the encoder motor is indexed correctly and the motor is flat against the transfer case before tightening the bolts. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 10778 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector (7). 6. Connect the transfer case switch electrical connector (2). 7. Install the front propeller shaft. 8. Install the transfer case shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 10779 Transfer Case Actuator: Service and Repair NVG 263-NP1 Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 10780 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair Case Adapter: Service and Repair Transfer Case Adapter Replacement Removal Procedure 1. Remove the transfer case. Refer to Transfer Case Assembly Replacement. 2. Remove the transfer case adapter bolts. 3. Remove the adapter. 4. Remove the adapter seal. Installation Procedure 1. Install a NEW seal onto the adapter. Important: Always use a new seal for the adapter. Do not use any type of sealant or adhesive in place of, or with the seal. 2. Install the adapter. Important: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the adapter bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the transfer case. Refer to Transfer Case Assembly Replacement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-04-19-002A > Feb > 11 > Drivetrain Excessive Effort When Shift 2HI to 4HI Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Page 10797 Case: Service and Repair Transfer Case Shield Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield bolts, if equipped. 3. Remove the transfer case shield, if equipped. Installation Procedure 1. Position the transfer case shield, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transfer case shield bolts, if equipped. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 10802 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 10805 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 Control Module: Diagrams NVG 246-NP8 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10808 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10809 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10810 Control Module: Diagrams NVG 263-NP1 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10811 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10812 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10815 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10816 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10817 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Fluid Transfer Case: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Fluid - Transfer Case: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case NVG 149 (RPO NP3) ........................................................................................................................... .......................................................... 2.1L (2.22 Qt) NVG 246 (RPO NP8) ........................................ .............................................................................................................................................. Not Specified NVG 261 (RPO NP2) ........................................................................................................... ........................................................................... Not Specified NVG 263 (RPO NPI) ......................... .............................................................................................................................................................. . 1.9L (2.0 Qt) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 10836 Fluid - Transfer Case: Fluid Type Specifications NVG 149-NP3 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 246-NP8 ......................................................................................... Auto-Trak II, transfer case fluid, GM P/N 12378508 (Canadian P/N 10953626) NVG 261-NP2 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 263-NP1 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Important: Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10839 2. Fill the transfer case to the bottom of the fill plug hole with DEXRON® III, GM P/N 12346143 (Canadian P/N 10952622). 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10840 Fluid - Transfer Case: Service and Repair NVG 246-NP8 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedures, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Install the drain plug. Tighten Tighten the plug to 20 N.m (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10841 2. Fill the transfer case to the bottom of the fill plug hole with Auto-Trak II, transfer case fluid, GM P/N 12378-508 (Canadian P/N 10953626). 3. Install the fill plug. Tighten Tighten the plug to 20 N.m (15 lb ft). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10842 Fluid - Transfer Case: Service and Repair NVG 261-NP2 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following service procedures, use only hand tools in order to remove and install the fill or drain plugs. Always start the plugs by hand in order to prevent cross threading. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: If the drain or fill plug have to be replaced, use only aluminum replacement drain plugs. Steel plugs will react with the magnesium of the transfer case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved transfer case fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10843 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10844 Fluid - Transfer Case: Service and Repair NVG 263-NP1 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10845 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 Four Wheel Drive Selector Switch: Locations NVG 246-NP8 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 > Page 10850 Four Wheel Drive Selector Switch: Locations NVG 263-NP1 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 Four Wheel Drive Selector Switch: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10853 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10854 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10855 Four Wheel Drive Selector Switch: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10856 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 10857 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 10858 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Gear Sensor/Switch: Service and Repair NVG 246-NP8 Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to Neutral prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench. 3. Remove and discard 2 screws (2) from the motor cover. 4. Remove and discard 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10863 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat-tipped screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10864 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler gear are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10865 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10866 Gear Sensor/Switch: Service and Repair NVG 261-NP2 Transfer Case Gear Indicator Switch Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the gear indicator switch electrical connector (2). 3. Remove the gear indicator switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the gear indicator switch. ^ Tighten the switch to 27 Nm (20 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10867 2. Connect the gear indicator switch electrical connector (2). 3. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10868 Gear Sensor/Switch: Service and Repair NVG 263-NP1 Encoder Motor Sensor Replacement Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10869 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10870 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10871 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Transfer Case Shift Control Switch Replacement Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 10877 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 10880 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 Control Module: Diagrams NVG 246-NP8 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10883 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10884 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10885 Control Module: Diagrams NVG 263-NP1 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10886 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 10887 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10890 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10891 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10892 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 Seals and Gaskets: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Driver Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screw driver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. Important: When performing the following service procedure, the outer part of the seal will slightly move out of the transfer case with the inner part seal. 6. Pry the inner part of the seal from the outer seal body. 7. Remove the inner part of the seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10897 8. Insert a flat-tipped screwdriver or small pry bar into the space between the lip of the outer race of the seal and the transfer case. 9. Pry the outer race out of the transfer case. 10. Remove the outer part of the seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10898 1. Install the J 43484 (2) to the J 8092 (1). 2. Install a NEW seal onto J 43484. 3. Using J 43484 (2), and J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level. Add fluid, if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Output Shaft Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Pry out the rear output shaft seal, using a flat-tipped screwdriver. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10899 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 into the front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Using the J 45380, install a NEW rear output shaft bushing. ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section to the main body of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10900 2. Using the J 37668-A, install a NEW front output shaft seal. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground. 3. Install the rear propeller shaft. 4. Check the fluid level. Add fluid, if necessary. 5. Install the transfer case shield, if equipped. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Front Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case. 2. Remove the input shaft seal, using a flat-tipped screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10901 1. Position the seal on the input shaft. Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (toward the technician). The input shaft seal should be even with the surface of the transfer case after installation. 2. Using the J 42738, install the input shaft seal. 3. Install the transfer case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10902 Seals and Gaskets: Service and Repair NVG 246-NP8 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Driver Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screwdriver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. 6. Remove the inner part of the seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10903 7. Insert a flat-tipped screwdriver or a small pry bar in the space between the outer race of the seal and the transfer case. 8. Remove the outer part of the seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10904 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the seal onto the J 43484. 3. Using the J 43484 (2) and the J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level, add fluid if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Remove the rear output shaft seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10905 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Install a NEW rear output shaft bushing, if required, using the J 45380. ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section to the main body of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10906 2. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground. Using the J 37668-A, install the rear output shaft to the transfer case. 3. Install the rear propeller shaft. 4. Check the fluid level, Add fluid if necessary. 5. Install the transfer case shield, if equipped. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Remove the transfer case. 2. Using a flat-tipped screwdriver, remove the input shaft seal. Installation Procedure Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (away from the body of the transfer case). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10907 1. Align the transfer case input shaft seal evenly on the input shaft. Important: The input shaft seal should be even with the surface of the transfer case after installation. 2. Using the J 42738, install the transfer case input shaft seal. 3. Install the transfer case. 4. Check the fluid level. Add fluid if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10908 Seals and Gaskets: Service and Repair NVG 261-NP2 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Drive Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screwdriver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. 6. Remove the inner part of the seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10909 7. Insert a flat-tipped screwdriver or a small pry bar in the space between the outer race of the seal and the transfer case. 8. Remove the outer part of the seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10910 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the seal onto the J 43484 (2). 3. Using the J 43484 (2) and the J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level, add fluid if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Remove the rear output shaft seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10911 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Install a NEW rear output shaft bushing, if required, using the J 45380. ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section to the main body of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10912 2. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground. Using the J 37668-A, install the rear output shaft seal. 3. Install the rear propeller shaft. 4. Check the fluid level, add fluid if necessary. 5. Install the transfer case shield, if equipped. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Remove the transfer case. 2. using a flat-tipped screwdriver, remove the input shaft seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10913 1. Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (away from the body of the transfer case). Align the transfer case input shaft seal evenly on the input shaft. 2. Important: The input shaft seal should be even with the surface of the transfer case after installation. Using the J 42738, install the transfer case input shaft seal. 3. Install the transfer case. 4. Check the fluid level. Add fluid of necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10914 Seals and Gaskets: Service and Repair NVG 263-NP1 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Driver Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screwdriver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. 6. Remove the inner part of the seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10915 7. Insert a flat-tipped screwdriver or small pry bar in the space between the outer race of the seal and the transfer case. 8. Remove the outer part of the seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10916 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the seal onto the J 43484 (2). 3. Using the J 43484 (2) and the J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level, add fluid if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Remove the rear output shaft seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10917 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Install a NEW rear output shaft bushing, if required using the J 45380 ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section to the main body of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10918 2. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground Using the J 37668-A, install the rear output shaft seal. 3. Install the rear propeller shaft. 4. Check the fluid level, add fluid if necessary. 5. Install the transfer case shield, if necessary. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Remove the transfer case. 2. Using a flat-tipped screwdriver, remove the input shaft seal. Installation Procedure Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (away from the body of the transfer case). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10919 1. Align the input seal evenly on the input shaft. Important: The input shaft seal should be even with the surface of the transfer case after installation. 2. Using the J 42738, install the input shaft seal. 3. Install the transfer case. 4. Check the fluid level, add fluid if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 Four Wheel Drive Selector Switch: Locations NVG 246-NP8 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 > Page 10925 Four Wheel Drive Selector Switch: Locations NVG 263-NP1 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 Four Wheel Drive Selector Switch: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10928 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10929 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10930 Four Wheel Drive Selector Switch: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 10931 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 10932 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 10933 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Gear Sensor/Switch: Service and Repair NVG 246-NP8 Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to Neutral prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench. 3. Remove and discard 2 screws (2) from the motor cover. 4. Remove and discard 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10938 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat-tipped screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10939 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler gear are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10940 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10941 Gear Sensor/Switch: Service and Repair NVG 261-NP2 Transfer Case Gear Indicator Switch Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the gear indicator switch electrical connector (2). 3. Remove the gear indicator switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the gear indicator switch. ^ Tighten the switch to 27 Nm (20 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10942 2. Connect the gear indicator switch electrical connector (2). 3. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10943 Gear Sensor/Switch: Service and Repair NVG 263-NP1 Encoder Motor Sensor Replacement Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10944 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10945 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 10946 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Transfer Case Shift Control Switch Replacement Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 10955 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 10961 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 10973 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10976 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10977 Speed Sensor: Service and Repair NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10978 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10979 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10980 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10981 Speed Sensor: Service and Repair NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10982 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10983 Speed Sensor: Service and Repair NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 10984 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair Shifter Transfer Case: Service and Repair Transfer Case Control Lever Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Remove the control rod. 4. Lower the vehicle. 5. Remove the control lever knob by performing the following: 1. Using an adjustable wrench, adjust the wrench to fit the control lever rod just below the knob. 2. With the adjustable wrench touching the control lever knob, gently tap on the adjustable wrench in an upward motion until the knob is separated from the control lever rod. 6. Remove the transfer case bezel screws. 7. Remove the transfer case bezel. 8. Important: When performing the following service procedure, the transfer case control lever bracket does not have to be removed from the vehicle. Remove the control lever bolts. 9. Remove the control lever assembly. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > Page 10988 1. Install the control lever assembly. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control lever bolts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the control lever bezel. 4. Install the control lever bezel screws. ^ Tighten the screws to 2 Nm (18 inch lbs.). 5. Install the control lever knob. 6. Raise and suitably support the vehicle. 7. Install the shift control rod. 8. Install the front propeller shaft. 9. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 10997 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 11003 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 11015 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11018 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11019 Speed Sensor: Service and Repair NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11020 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11021 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11022 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11023 Speed Sensor: Service and Repair NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11024 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11025 Speed Sensor: Service and Repair NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11026 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 Transfer Case Actuator: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 11031 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 11032 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 11033 Transfer Case Actuator: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 11034 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 Transfer Case Actuator: Service and Repair NVG 246-NP8 Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield. 2. Remove the front propeller shaft. 3. Disconnect the transfer case switch electrical connector (2). 4. Disconnect the encoder motor electrical connector (7). 5. Remove the encoder motor bolts. 6. Remove the encoder motor. 7. Remove the actuator insulator gasket. 8. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the transfer case at the shift shaft, using a crescent wrench if necessary. ^ When installing the encoder motor, ensure that the encoder motor is indexed correctly and the motor is flat against the transfer case before tightening the bolts. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 11037 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector (7). 6. Connect the transfer case switch electrical connector (2). 7. Install the front propeller shaft. 8. Install the transfer case shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 11038 Transfer Case Actuator: Service and Repair NVG 263-NP1 Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 11039 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Pressure Regulating Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11047 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11048 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11049 Pressure Regulating Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 11052 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 11053 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 11054 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Transmission Shift Lock Control Actuator Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 11058 Shift Interlock Solenoid: Description and Operation Automatic Transmission Shift Lock Control Description and Operation Automatic Transmission Shift Lock Control System The automatic transmission shift lock control is a safety device that prevents an inadvertent shift out of PARK when the ignition is ON. The driver must press the brake pedal before moving the shift lever out of the PARK position. The system consists of the following components: ^ The automatic transmission shift lock control solenoid. ^ The automatic transmission shift lock control switch. ^ The park/neutral position switch. With the ignition in the ON position, battery positive voltage is supplied to the park/neutral position switch. When the transmission is in the PARK position the contacts in the park/neutral position switch are closed. This allows current to flow through the switch to the automatic transmission shift lock control switch. The circuit continues through the normally-closed switch to the automatic transmission shift lock control solenoid. The automatic transmission shift lock control solenoid is permanently grounded. This energizes the automatic transmission shift lock control solenoid, locking the shift linkage in the PARK position. When the driver presses the brake pedal the contacts in the automatic transmission shift lock control switch open, causing the automatic transmission shift lock control solenoid to release. This allows the shift lever to move from the PARK position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 11059 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to Restraint Systems Caution in Service Precautions. Disable the Restraint system. Refer to Restraint Systems Disabling and Enabling Zone 3 in Restraint Systems. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 11060 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the Body Control Module. 6. Enable the Restraint systems. Refer to Restraint Systems Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 11065 Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Shift Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11068 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11069 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11070 Shift Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Shift Solenoid: Diagrams 4L60-E/4L65-E 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 11073 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 11074 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 11075 Shift Solenoid: Diagrams 4L80-E/4L85-E 1-2 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 11076 2-3 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 11077 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 11078 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 11079 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 11080 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E Torque Converter Clutch Solenoid: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11085 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11086 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11087 Torque Converter Clutch Solenoid: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E Torque Converter Clutch Solenoid: Diagrams 4L60-E/4L65-E Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 11090 Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side (M30)/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 11091 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 11092 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector.Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 11093 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 11094 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 11095 ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 11096 ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 Transfer Case Actuator: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 11102 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 11103 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 11104 Transfer Case Actuator: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > NVG 246-NP8 > Page 11105 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 Transfer Case Actuator: Service and Repair NVG 246-NP8 Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield. 2. Remove the front propeller shaft. 3. Disconnect the transfer case switch electrical connector (2). 4. Disconnect the encoder motor electrical connector (7). 5. Remove the encoder motor bolts. 6. Remove the encoder motor. 7. Remove the actuator insulator gasket. 8. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the transfer case at the shift shaft, using a crescent wrench if necessary. ^ When installing the encoder motor, ensure that the encoder motor is indexed correctly and the motor is flat against the transfer case before tightening the bolts. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 11108 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector (7). 6. Connect the transfer case switch electrical connector (2). 7. Install the front propeller shaft. 8. Install the transfer case shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 11109 Transfer Case Actuator: Service and Repair NVG 263-NP1 Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NVG 246-NP8 > Page 11110 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation SHIFT INDICATOR The instrument panel cluster (IPC) illuminates the shift indicator when the powertrain control module (PCM) determines that the vehicle should be shifted to the next higher gear. The IPC receives a class 2 message from the PCM requesting illumination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls - Shared Diagnostic Trouble Codes Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 11127 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 11130 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 Control Module: Diagrams NVG 246-NP8 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 11133 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 11134 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 11135 Control Module: Diagrams NVG 263-NP1 Transfer Case Shift Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 11136 Transfer Case Shift Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > NVG 246-NP8 > Page 11137 Transfer Case Shift Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11140 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11141 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11142 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Automatic Transmission Shift Lock Control Component Views Lower Steering Column Components Lower Steering Column Components 1 - A/T Shift Lock Control Actuator 2 - Steering Column Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 4L60-E/4L65-E > Page 11152 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Fluid Pressure Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11155 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11156 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11157 Fluid Pressure Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side (M30/M32) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 11160 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 11161 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 11162 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 11163 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Remove the remaining valve body bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 11164 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 21. Remove the seven valve body checkballs. 22. Remove the accumulator cover bolts (58, 59). 23. Remove the 1-2 accumulator cover and pin assembly (57). 24. Remove the spacer plate support bolts (77). 25. Remove the spacer plate support (53). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 11165 26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). 2. Notice: Refer to Fastener Notice in Service Precautions. Install the spacer plate support (53) and bolts (77). ^ Tighten the bolts to Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 11166 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). ^ Tighten the bolts to 10 Nm (89 inch lbs.). Ball Check Valves 5. Install the seven checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 11167 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 9. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Do not install the transmission fluid indicator stop bracket and bolt at this time.Install but do not tighten the valve body bolts which retain only the valve body directly.Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 11168 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). 15. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 11169 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 11170 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 24. Install the auxiliary pump, if equipped with RPO HP2. 25. Install the transmission filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Diagrams > 4L60-E/4L65-E > Page 11175 Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 11178 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 11179 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 11180 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E > Page 11185 Transmission Range Switch Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E > Page 11188 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 11191 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 11192 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 11193 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 11194 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 11195 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Speed Sensor: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11200 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11201 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11202 Transmission Speed Sensor: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E Transmission Speed Sensor: Diagrams 4L80-E/4L85-E Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 11205 Automatic Transmission Output Shaft Speed (AT OSS) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L80-E/4L85-E > Page 11206 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E Transmission Speed Sensor: Service and Repair 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 11209 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 11210 Transmission Speed Sensor: Service and Repair 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 11211 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 11212 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E > Page 11213 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > 4L80-E/4L85-E > Page 11218 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E Transmission Temperature Sensor/Switch: Locations 4L60-E/4L65-E Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 108 - Secondary Fluid Pump Assembly - M33 Models Only 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Vehicle Speed Sensor (VSS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11221 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E 2 - Park/Neutral Position (PNP) Switch C175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11222 C175 1 - Automatic Transmission 2 - C175 Tow/Haul Switch Location Tow/Haul Switch Location 1 - Tow/Haul Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4L60-E/4L65-E > Page 11223 Transmission Temperature Sensor/Switch: Locations 4L80-E/4L85-E Automatic Transmission Electronic Component Views Automatic Transmission Internal Electronic Components (4L80-E) Automatic Transmission Internal Electronic Components (4L80-E) 22a - Automatic Transmission (AT) Input (Shaft) Speed Sensor (ISS) Assembly 22b - Automatic Transmission (AT) Output (Shaft) Speed Sensor (OSS) Assembly 34 - Automatic Transmission Fluid Temperature (TFT) Sensor 40 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 311 - 2-3 Shift Solenoid (SS) Valve Assembly 313 - 1-2 Shift Solenoid (SS) Valve Assembly 320 - Pressure Control (PC) Solenoid Valve Assembly 323 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 11224 Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 Transmission Speed Sensor: Locations NV 3500 Manual Transmission Component Views Manual Transmission - NV 3500 Manual Transmission - NV 3500 1 - Vehicle Speed Sensor 2 - NV 3500 Transmission 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 11230 Transmission Speed Sensor: Locations NV 4500 Manual Transmission Component Views Manual Transmission - NV 4500 Manual Transmission - NV 4500 1 - Backup Lamp Switch 2 - Oxygen Sensor Downstream Connector 3 - Vehicle Speed Connector 4 - NV 4500 Transmission 5 - Oxygen Sensor Upstream Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > NV 3500 > Page 11231 Transmission Speed Sensor: Locations ZF S6-650 Manual Transmission Component Views Manual Transmission - ZF S6-650 Manual Transmission - ZF S6-650 1 - Oxygen Sensor Upstream Connector 2 - PTO Relay 3 - Oxygen Sensor Downstream Connector 4 - Backup Lamp Switch 5 - Vehicle Speed Sensor 6 - ZF S6-650 Transmission Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 11234 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > NV 3500 > Page 11235 Vehicle Speed Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 11238 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 11239 Transmission Speed Sensor: Service and Repair NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 11240 3. Connect the VSS electrical connector (3).Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 11241 Transmission Speed Sensor: Service and Repair ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle. 2. If equipped with the 6.6L engine , disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > NV 3500 > Page 11242 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine , connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 Four Wheel Drive Selector Switch: Locations NVG 246-NP8 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > NVG 246-NP8 > Page 11248 Four Wheel Drive Selector Switch: Locations NVG 263-NP1 Transfer Case Shift Control Switch Transfer Case Shift Control Switch 1 - Transfer Case Shift Control Switch 2 - Instrument Panel Switch and Deflector Housing Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 Four Wheel Drive Selector Switch: Diagrams NVG 246-NP8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 11251 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 11252 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 11253 Four Wheel Drive Selector Switch: Diagrams NVG 263-NP1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > NVG 246-NP8 > Page 11254 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 11255 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 11256 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Gear Sensor/Switch: Service and Repair NVG 246-NP8 Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to Neutral prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench. 3. Remove and discard 2 screws (2) from the motor cover. 4. Remove and discard 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11261 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat-tipped screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11262 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler gear are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11263 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11264 Gear Sensor/Switch: Service and Repair NVG 261-NP2 Transfer Case Gear Indicator Switch Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the gear indicator switch electrical connector (2). 3. Remove the gear indicator switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the gear indicator switch. ^ Tighten the switch to 27 Nm (20 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11265 2. Connect the gear indicator switch electrical connector (2). 3. Install the transfer case shield, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11266 Gear Sensor/Switch: Service and Repair NVG 263-NP1 Encoder Motor Sensor Replacement Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11267 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11268 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. 12. Install the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 11269 Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Transfer Case Shift Control Switch Replacement Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 11278 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 11284 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 11296 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11299 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11300 Speed Sensor: Service and Repair NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11301 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11302 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11303 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11304 Speed Sensor: Service and Repair NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11305 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11306 Speed Sensor: Service and Repair NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 11307 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams Brake Pedal Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 11321 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 11327 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11328 Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11329 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (ECBM) C1 Electronic Brake Control Module (ECBM) C2 (8600 GVW or Less w/Rear Disc Brakes Electronic Brake Control Module (ECBM) C2 (Over 8600 GVW or Rear Drum Brakes Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11330 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11331 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 4. Disconnect the chassis electrical connectors from the EBCM. 5. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11332 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 7. Disconnect the BPMV electrical connector from the EBCM. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11333 1. Connect the BPMV electrical connector to the EBCM. 2. Install the EBCM to the BPMV. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the new screws (1) in the EBCM (2). Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11334 4. connect the chassis electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Remove the negative battery cable. 2. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 3. Disconnect the chassis electrical harness connectors from the EBCM. 4. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. Disconnect 5 brake lines from the BPMV. 5. Remove the bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 6. Remove the EHCU assembly (1) from the vehicle. 7. Remove the bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). 8. Disconnect the 2 way ABS pump motor connector. 9. Remove the bolts (1) from the EBCM (2). 10. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. 11. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 11338 Installation Procedure 1. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Install the EBCM (2) onto BPMV (3). 2. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. Install the four EBCM bolts. Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM. 4. Install the BPMV (3) to BPMV bracket (5). 5. Install the BPMV to bracket retaining bolts (4). Tighten the bolts to 9 Nm (7 ft. lbs.). 6. Install the EHCU assembly (1, 2) to the vehicle frame (5). Tighten the three EHCU bracket bolts (4) to 25 Nm (18 ft. lbs.). 7. Connect the chassis electrical harness connectors to the EBCM (1). 8. Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. Install the 5 brake pipes to the BPMV (6). Tighten the brake pipe fittings to 25 Nm (18 ft. lbs.). 9. Connect negative battery cable. 10. Bleed the brake system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams Traction Control Switch: Diagrams Traction Control Switch (NW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Page 11342 Traction Control Switch: Service and Repair Traction Control Switch Replacement (Stabilitrak) Removal Procedure 1. Remove the Instrument Panel (I/P) bezel. 2. Gently lift the retaining tabs (2) and remove the stabilitrak switch (3) from the I/P assembly (1). 3. Disconnect the harness connector from the stabilitrak switch. Installation Procedure 1. Connect the harness connector to the stabilitrak switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Page 11343 2. Install the stabilitrak switch (3) into the I/P assembly (1) 3. Ensure that the switch is secure into both retaining tabs (2). 4. Install the I/P bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 11352 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 11358 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11359 Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11360 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) LF Wheel Speed Sensor (WSS) RF Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11361 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Front (4 Wheel Drive) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2) shown on the 1500 Series. 4. Remove the Wheel Speed Sensor (WSS) cable mounting clip from the knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Remove the WSS cable electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11362 8. Remove the WSS mounting bolt. 9. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the WSS (5) from the hub/bearing assembly (4) shown on the 2500/3500 series. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to sensor installation. 4. Install the WSS (5) into the hub/bearing assembly (4) shown on the 2500/3500 series. Ensure that the sensor is seated flat against the hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11363 5. Notice: Refer to Fastener Notice in Service Precautions. Install the WSS mounting bolt. Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. 9. Connect the WSS cable electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11364 10. Install the brake rotor (2) shown on the 1500 Series. 11. Install the tire and wheel. 12. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice; When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11 GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. 10. With the ignition OFF, apply the brakes 3 - 5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11369 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3 - 5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11370 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 23. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11371 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Tools Required ^ J29532 Diaphragm Type Brake Pressure Bleeder, or equivalent ^ J35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3 - 5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J29532, or equivalent, to the J35589-A. 8. Charge the J29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11372 tightened. 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J35589-A. 23. Remove the J35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11373 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing HYDRAULIC BRAKE SYSTEM FLUSHING Caution: Brake fluid may irritate eyes and skin. In case of contact, take the following actions: * Eye contact--rinse thoroughly with water. * Skin contact--wash with soap and water. * If ingested--consult a physician immediately. Notice: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: » Fluid separation, indicating two types of fluid are present. A substance other than the recommended brake fluid has been introduced into the brake hydraulic system. - Swirled appearance--Oil-based substance - Layered appearance--Silicone-based substance » Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system. - Cloudy appearance--Moisture - Dark appearance/suspended particles in fluid--Dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 3.1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid. Refer to the procedures indicated. - Master Cylinder Replacement - Front Brake Hose Replacement - Rear Brake Hose Replacement - Front Brake Caliper Replacement - Rear Brake Caliper Replacement - Brake Pressure Modulator Valve Replacement 3.2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3.3. Dry the brake pipes using non-lubricated, filtered air. 3.4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated. - Master Cylinder Replacement - Also perform the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11374 - Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement . - Replace the brake master cylinder reservoir cap diaphragm. - Front Brake Hose Replacement - Rear Brake Hose Replacement - Front Brake Caliper Overhaul or Front Brake Caliper Replacement - Rear Brake Caliper Overhaul or Rear Brake Caliper Replacement - Brake Pressure Modulator Valve Replacement 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11375 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11 (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Removal Procedure 1. Remove the pushrod retaining clip (4). 2. Remove the stop lamp switch (2) and the pushrod (3) from the brake pedal stud (1). 3. Remove the nut from the brake pedal bolt. 4. Remove the brake pedal bolt. 5. Remove the brake pedal. Installation Procedure 1. Install the brake pedal. 2. Install the brake pedal bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the nut to the brake pedal bolt. Hold the nut with a wrench and tighten the brake pedal bolt to 47 Nm (35 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 11379 4. Install the pushrod (3) and the stop lamp switch (2) to the brake pedal pin (1). 5. Install the pushrod retaining clip (4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11384 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11385 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11386 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11387 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11388 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11389 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11390 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11391 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11392 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11393 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11394 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11395 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11396 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11397 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11398 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11399 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11400 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11401 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11402 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11403 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11404 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11405 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11406 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11407 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11408 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11409 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11410 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11411 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11412 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11413 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11414 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11415 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11416 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11417 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11418 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11419 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11420 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11421 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11422 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11423 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11424 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11425 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11426 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11427 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11428 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11429 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11430 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11431 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11432 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11433 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11434 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11435 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11436 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11437 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11438 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11439 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11440 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11441 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11442 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11443 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11444 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11445 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11446 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11447 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11448 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11449 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11450 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11451 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11452 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11453 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11454 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11455 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11456 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11457 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11458 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11459 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11460 Brake Warning Indicator: Electrical Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11461 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Raise and support the vehicle. 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. 1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamps from the caliper. 7. Clean all dirt and foreign material from around the brake hose fitting. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. 8. Remove the brake hose to caliper bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11467 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the caliper or the brake hose end. 10. Remove the brake hose from the caliper. 11. Remove the brake caliper bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the caliper from the caliper bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11468 1. Install the caliper to the caliper bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. 4. Assemble 2 NEW copper brake hose gaskets to the brake hose bolt, and brake hose. 5. Install the brake hose to caliper bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11469 Tighten the bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11470 Brake Caliper: Service and Repair Brake Caliper Replacement - Rear W/O NYS Brake Caliper Replacement - Rear (1500 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Remove the tire and wheel assembly. 5. Compress the brake caliper piston. 1. Install a C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. 6. Clean all dirt and foreign material from the brake hose fitting. 7. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11471 Remove the brake hose to caliper bolt. 8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the caliper or the brake hose end. 9. Remove the brake hose from the caliper. 10. Remove the brake caliper bolts. 11. Remove the caliper from the caliper bracket. Installation Procedure 1. Important: Use denatured alcohol to clean the outside surface of caliper boot before installing new brake pads. If installing NEW brake pads, use a C-clamp in order to compress the piston to the bottom of the caliper bore. Use the old brake pad, a metal plate or a wooden block across the face of the piston in order to protect the piston and the caliper boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11472 2. Important: Use a small flat-bladed tool and lift the inner edge caliper boot next to the piston to release any trapped air. Ensure that the piston boot is below the level of the piston face. 3. Install the caliper to the caliper bracket. 4. Perform the following procedure before installing the brake caliper bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11473 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bolts. Tighten the bolts to 42 Nm (31 ft. lbs.). 6. Remove the rubber cap or plug from the exposed brake hose fitting end. 7. Important: Install 2 NEW copper brake hose gaskets. Assemble the 2 NEW copper brake hose gaskets to the brake hose bolt and brake hose. 8. Install the brake hose to caliper bolt. Tighten the bolt to 40 Nm (30 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. W/NYS Brake Caliper Replacement - Rear (1500 Series w/NYS, 25/3500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11474 before proceeding. 4. Remove the tire and wheel assembly. 5. Compress the brake caliper pistons. 1. Install a large C-clamp over the body of the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. 6. Clean all dirt and foreign material from the brake hose fitting. 7. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt. 8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the caliper or brake hose end. 9. Remove the brake hose from the caliper. 10. Loosen the brake caliper bolts. DO NOT remove. 11. Remove the brake caliper bracket bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the caliper and caliper bracket as an assembly. 13. Remove the brake caliper bolts. 14. Remove the caliper from the caliper bracket. 15. Inspect the caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11475 16. Remove the brake pads from the caliper bracket. 17. Remove the anti-rattle clips. 18. Inspect the caliper bracket for cracks and/or damage. Replace if necessary. 19. Inspect the caliper bracket bushings for damage and/or wear. Replace the bushings if necessary. 20. Perform the following procedure to replace the brake caliper bracket bushings. 1. Insert a flat-bladed tool between the bushing flange and the bracket. 2. Work the tool around the bushing flange and remove the bushing from the bracket. 3. Place a socket over the boot onto the bushing flange and install the bushing to the bracket. Installation Procedure 1. Install the anti-rattle clips to the caliper bracket. 2. Install the brake pads. 3. Install the caliper to the caliper bracket. 4. Perform the following procedure before installing the caliper bracket bolts and the caliper bolts: 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 5. Install the brake caliper bolts. DO NOT tighten. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11476 6. Install the caliper and caliper bracket as an assembly. 7. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket bolts. Tighten the bolts to 300 Nm (221 ft. lbs.). 8. Tighten the brake caliper bolts. Tighten the bolts to 108 Nm (80 ft. lbs.). 9. Remove the rubber cap or plug from the exposed brake hose fitting end. 10. Important: Install 2 NEW copper brake hose gaskets. Assemble the 2 NEW copper brake hose gaskets to the brake hose bolt and brake hose. 11. Install the brake hose to caliper bolt. Tighten the bolt to 40 Nm (30 ft. lbs.). 12. Bleed the hydraulic brake system. 13. Install the tire and wheel assembly. 14. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11477 Brake Caliper: Service and Repair Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear (1500 Series w/NYS, 25/3500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Disassembly Procedure Important: ^ Replace all the components included in the repair kits used to service this brake caliper. ^ Lubricate the rubber parts with clean brake fluid to make assembly easier. ^ The torque values specified are for dry, non lubricated fasteners. ^ Perform the service operations on a clean bench, free from all mineral oil materials. 1. Remove the brake caliper. 2. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Place a thin piece wood in front of the pistons in order to prevent damage. Remove the pistons by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the pistons. 4. Remove the piston boots. 5. Remove the piston seals. 6. Remove the caliper bleed screw cap. 7. Remove the caliper bleed screw. 8. Inspect the caliper bores and the piston seal grooves for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal areas replace the brake caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11478 9. Inspect the caliper bracket guide surfaces for corrosion and wear. Remove and replace the caliper bracket, if necessary. 10. Clean all of the residue from the brake pad guiding surfaces on the caliper and the caliper bracket. 11. Clean all the parts not included in the repair kit with denatured alcohol. 12. Dry all the parts with non lubricated filtered compressed air. 13. Blow out all passages in the caliper and the caliper bleeder valve. Assembly Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bleed screw. Tighten the screw to 12 Nm (106 inch lbs.). 2. Install the caliper bleed screw cap. 3. Lubricate the new piston seals and the brake caliper bore seal grooves with brake fluid. 4. Install NEW seals into the brake caliper bore seal grooves. 5. Ensure that the seals are not twisted. 6. Lubricate the caliper bores and the pistons with brake fluid. 7. Install the boots and pistons. 1. Install the boots over the end of the pistons so that the fold will face toward the brake caliper housing piston bore openings. 2. Seat the boost into the brake caliper bore grooves. Slide the pistons into the brake caliper bores. 3. Push down the pistons to the bottom of the brake caliper bores. 4. Ensure that the boots are properly seated into the piston grooves and into the grooves in the brake caliper bores. 8. Install the brake caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11479 Brake Caliper: Service and Repair Brake Caliper Bracket Replacement - Front Brake Caliper Bracket Replacement - Front (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Remove the tire and wheel assembly. 5. Compress the brake caliper pistons. 1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamps from the caliper. 6. Remove the brake caliper bolts. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11480 7. Notice: Refer to Brake Caliper Notice in Service Precautions. Remove the caliper from the caliper bracket. Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. 8. Remove the brake pads from the caliper bracket. 9. Remove the anti-rattle clips. 10. Remove the brake caliper bracket bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11481 11. Remove the brake caliper bracket. 12. Remove any contaminants or foreign material from the inside ends of the caliper bracket. 13. Clean the mounting surface and threads of the caliper bracket. Installation Procedure 1. Install the brake caliper bracket. 2. Perform the following procedure before installing the brake caliper bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11482 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket bolts. Tighten the bolts to 180 Nm (133 ft. lbs.). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads. 6. Slide the brake pads in until they contact the rotor. 7. Install the caliper to the caliper bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11483 8. Install the brake caliper bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). 9. Install the tire and wheel assembly. 10. Lower the vehicle. 11. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 12. Slowly release the brake pedal. 13. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the caliper pistons and pads. 14. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11484 Brake Caliper: Service and Repair Brake Caliper Bracket Replacement - Rear Brake Caliper Bracket Replacement - Rear (1500 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Remove the tire and wheel assembly. 5. Compress the brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. 6. Remove the brake caliper bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11485 7. Notice: Refer to Brake Caliper Notice in Service Precautions. Remove the caliper from the caliper bracket. Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. 8. Remove the brake pads from the caliper bracket. 9. Remove the anti-rattle clips. 10. Remove the brake caliper bracket bolts. 11. Remove the brake caliper bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11486 12. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 13. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure 1. Install the brake caliper bracket. 2. Perform the following procedure before installing the brake caliper bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket bolts. Tighten the bolts to 200 Nm (148 ft. lbs.). 4. Install the anti rattle clips to the brake caliper bracket. 5. Install the brake pads. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11487 6. Install the caliper to the caliper bracket. 7. Install the brake caliper bolts. Tighten the bolts to 42 Nm (31 ft. lbs.). 8. Install the tire and wheel assembly. 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the caliper pistons and pads. 12. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 inch) of the audible wear sensors. Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If more than 0.13 mm (0.005 inch) gap exists midway between the length of the disc brake pads, replace the disc brake pads. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Replacement - Front Brake Pad: Service and Repair Replacement - Front Brake Pads Replacement - Front (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Remove the tire and wheel assembly. 5. Compress the brake caliper pistons. ^ Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamps from the caliper. 6. Remove the lower brake caliper bolt. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Replacement - Front > Page 11493 7. Rotate the caliper upwards. 8. Remove the brake pads from the caliper bracket. 9. Remove and discard the anti-rattle clips. 10. Inspect the caliper and caliper bracket. Installation Procedure 1. Install NEW anti-rattle clips to the caliper bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Replacement - Front > Page 11494 2. Install the brake pads to the caliper bracket. The inner pad has 1 wear indicator, the outer pad has none. 3. Rotate the caliper back down and into place. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the lower brake caliper bolt. Tighten the bolt to 100 Nm (74 ft. lbs.). 5. Install the tire and wheel assembly. 6. Remove the safety stands. 7. Lower the vehicle. 8. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 9. Slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained. This will properly seat the brake caliper pistons and pads. 11. Fill the brake master cylinder reservoir to the proper level with clean brake fluid, if necessary. 12. Burnish the pads and rotors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Replacement - Front > Page 11495 Brake Pad: Service and Repair Replacement - Rear Brake Pads Replacement - Rear (1500 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Remove the tire and wheel assembly. 5. Compress the brake caliper piston. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. 6. Remove the brake caliper bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Replacement - Front > Page 11496 7. Notice: Refer to Brake Caliper Notice in Service Precautions. Remove the caliper from the caliper bracket. Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 8. Remove the brake pads from the caliper bracket. 9. Remove the brake pad retainers. 10. Inspect the caliper and caliper bracket. Installation Procedure 1. Using a C-clamp (1), bottom the piston into the caliper bore. Use an old brake pad (2) or wooden block placed across the face of the piston. Do not damage the piston or the caliper boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Replacement - Front > Page 11497 2. Important: Use a small flat-bladed tool and lift the inner edge caliper boot next to the piston to release any trapped air. Ensure that the piston boot is below the level of the piston face. 3. Install the brake pad retainers to the caliper bracket. 4. Important: Ensure that the wear sensor is positioned at the leading edge, upward, of the inner pad during forward wheel rotation. Install the brake pads. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Replacement - Front > Page 11498 5. Install the caliper to the caliper bracket. 6. Notice: Refer to Fastener Notice in Service Precautions. Install NEW brake caliper bolts. Tighten the bolts to 108 Nm (80 ft. lbs.). 7. Install the tire and wheel assembly. 8. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 9. Slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 9-10 until a firm pedal is obtained. This will properly seat the caliper pistons and pads. 11. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. 12. Burnish the pads and the rotors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Replacement - Front > Page 11499 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Refer to Road Test Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11504 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11505 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11506 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11507 WARRANTY INFORMATION Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11508 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11509 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11510 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11511 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11512 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11513 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11514 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11515 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11516 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11517 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11518 Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor/Drum Refinishing Labor Operations Bulletin No.: 06-05-22-007 Date: November 30, 2006 WARRANTY ADMINISTRATION Subject: Brake Rotor/Drum Refinishing Labor Operations Models: 2005-2007 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X (Canada Only) The purpose of this bulletin is to advise dealership personnel of labor operation changes relating to brake repairs. Existing brake rotor and drum labor operations have been revised to remove the refinishing times and new labor operations have been established for refinishing brake rotors or drums. The changes will become effective with the release of the December 2006 Labor Time Guide. The following changes: Applies to all 2005-2007 vehicles, unless 2005 was the last year of production for that particular model. May apply to 2004 and prior models years if the vehicle was produced after 2005 - e.g. TrailBlazer, Envoy, etc. Where the new labor operations for refinishing rotors or drums do not apply, the existing labor operations will still contain time for refinishing. Always refer to the Labor Time Guide for the appropriate labor operations and time for the vehicle being repaired. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11519 The list shown is of labor operations for brake service. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 11520 Brake Rotor/Disc: Specifications Front Brakes (RPO JC4) Rotor Discard Thickness * ............................................................................................................................................................. 27.50 mm (1.082 inch) Rotor Minimum Allowable Thickness After Refinish ....................................................................................................................... 28.0 mm (1.10 inch) Rotor Thickness (new) ......................................................................................................................... .............................................. 29.0 mm (1.14 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.059 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Front Brakes (RPO's JF3/JF7) Rotor Discard Thickness * ................................................................................................................... .............................................. 28.0 mm (1.10 inch) Rotor Minimum Allowable Thickness After Refinish ....................................................................................................................... 28.0 mm (1.10 inch) Rotor Thickness (new) ................................................................................................................ ..................................................... 30.0 mm (1.181 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.05 mm (0.002 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.059 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Front Brakes (RPO JH1) Rotor Discard Thickness * ............................................................................................................................................................. 27.50 mm (1.082 inch) Rotor Minimum Allowable Thickness After Refinish ....................................................................................................................... 28.0 mm (1.10 inch) Rotor Thickness (new) ......................................................................................................................... .............................................. 29.0 mm (1.14 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.059 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Front Brakes (RPO JH6) Rotor Discard Thickness * ............................................................................................................................................................. 36.50 mm (1.437 inch) Rotor Minimum Allowable Thickness After Refinish ....................................................................................................................... 37.0 mm (1.46 inch) Rotor Thickness (new) ......................................................................................................................... .............................................. 38.0 mm (1.50 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.059 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Front Brakes (RPO JH7) Rotor Discard Thickness * ............................................................................................................................................................. 36.50 mm (1.437 inch) Rotor Minimum Allowable Thickness After Refinish ....................................................................................................................... 37.0 mm (1.46 inch) Rotor Thickness (new) ......................................................................................................................... .............................................. 38.0 mm (1.50 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.059 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Rear Brakes (RPO JC4) Rotor Discard Thickness * ............................................................................................................................................................. 28.50 mm (1.122 inch) Rotor Minimum Allowable Thickness After Refinish ..................................................................................................................... 29.0 mm (1.142 inch) Rotor Thickness (new) ......................................................................................................................... ............................................ 30.0 mm (1.181 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.059 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Rear Brakes (RPO JH1) Rotor Discard Thickness * ............................................................................................................................................................. 18.50 mm (0.728 inch) Rotor Minimum Allowable Thickness After Refinish ..................................................................................................................... 19.0 mm (0.748 inch) Rotor Thickness (new) ......................................................................................................................... ............................................ 20.0 mm (0.787 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.059 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Rear Brakes (RPO JH6) Rotor Discard Thickness * ............................................................................................................................................................. 27.50 mm (1.082 inch) Rotor Minimum Allowable Thickness After Refinish ..................................................................................................................... 28.0 mm (1.102 inch) Rotor Thickness (new) ......................................................................................................................... ............................................ 29.0 mm (1.141 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.059 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 11521 Rear Brakes (RPO JH7) Rotor Discard Thickness * ................................................................................................................... ............................................ 28.5 mm (1.122 inch) Rotor Minimum Allowable Thickness After Refinish ..................................................................................................................... 29.0 mm (1.142 inch) Rotor Thickness (new) ................................................................................................................ ..................................................... 30.0 mm (1.181 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.059 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) * All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace any rotor that does not meet the minimum thickness specifications. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Refer to Road Test Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11524 Brake Rotor/Disc: Service and Repair Disc Brake Backing Plate Replacement - Rear 1500 Series With RPO NYS Disc Brake Backing Plate Replacement - Rear (1500 Series w/NYS) Caution; Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake, if necessary. 2. Remove the tire and wheel assembly. 3. Relieve the tension from the park brake cable by pulling down on the intermediate cable then release the cable from the equalizer bar. 4. Remove the rear park brake bracket bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11525 5. Remove the park brake cable from the park brake actuator lever. 6. Remove the wheel bearing. 7. Remove the park brake shoe. 8. Remove the park brake actuator lever housing from the backing plate. 9. Remove the backing plate. Installation Procedure 1. Install the park brake actuator lever housing to the backing plate. 2. Install the park brake shoe. 3. Install the wheel bearing and adjust the park brake shoe. 4. Install the park brake cable to the park brake actuator lever. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake bracket bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11526 6. Install the park brake cable to the equalizer bar. 7. Install the tire and wheel assembly. Without RPO NYS Disc Brake Backing Plate Replacement - Rear (1500 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Remove the park brake actuator. 2. Remove the backing plate bolts. 3. Remove the backing plate from the axle housing flange. Installation Procedure 1. Install the backing plate to the axle housing flange. 2. Perform the following procedure before installing the backing plate bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the backing plate bolts. Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11527 4. Install the park brake actuator. 5. Adjust the park brake shoe. 6. Adjust park brake cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11528 Brake Rotor/Disc: Service and Repair Disc Brake Splash Shield Replacement - Front 1500 Series Disc Brake Splash Shield Replacement - Front (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Remove the hub and bearing assembly. 2. Remove the splash shield. Installation Procedure 1. Install the splash shield. 2. Install the hub and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11529 Brake Rotor/Disc: Service and Repair Replacement - Front 1500 Series Brake Rotor Replacement - Front (1500 Series) Tools Required ^ J41013 Rotor Resurfacing Kit ^ J42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable. 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Remove the tire and wheel assembly. 5. Mark the relationship of the rotor to the hub. 6. Compress the brake caliper pistons. 1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamps from the caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11530 7. Remove the brake caliper bracket bolts. 8. Notice: Refer to Brake Caliper Notice in Service Precautions. Remove the caliper and caliper bracket as an assembly. Support the caliper assembly with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 9. Remove the brake rotor retaining push nuts from the wheel studs, if necessary. 10. Remove the brake rotor screw. 11. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub. 12. Remove the rotor. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11531 4. Important: If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. Align the rotor to its original position on the hub (if applicable) and install the rotor. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the brake rotor screw. Tighten the screw to 12 Nm (106 inch lbs.). 6. If the rotor was removed and installed as part of a brake system repair, measure the assembled Lateral Runout (LRO) of the rotor to ensure optimum performance of the disc brakes. 7. If the rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. 8. Install the caliper and caliper bracket as a assembly. 9. Perform the following procedure before installing the caliper bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 10. Install the brake caliper bracket bolts. Tighten the bolts to 180 Nm (133 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the caliper pistons and pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11532 Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Refer to Road Test Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. With RPO NYS Disc Brake Backing Plate Replacement - Rear (1500 Series w/NYS) Caution; Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake, if necessary. 2. Remove the tire and wheel assembly. 3. Relieve the tension from the park brake cable by pulling down on the intermediate cable then release the cable from the equalizer bar. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11533 4. Remove the rear park brake bracket bolt. 5. Remove the park brake cable from the park brake actuator lever. 6. Remove the wheel bearing. 7. Remove the park brake shoe. 8. Remove the park brake actuator lever housing from the backing plate. 9. Remove the backing plate. Installation Procedure 1. Install the park brake actuator lever housing to the backing plate. 2. Install the park brake shoe. 3. Install the wheel bearing and adjust the park brake shoe. 4. Install the park brake cable to the park brake actuator lever. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake bracket bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11534 6. Install the park brake cable to the equalizer bar. 7. Install the tire and wheel assembly. Without RPO NYS Disc Brake Backing Plate Replacement - Rear (1500 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Remove the park brake actuator. 2. Remove the backing plate bolts. 3. Remove the backing plate from the axle housing flange. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11535 1. Install the backing plate to the axle housing flange. 2. Perform the following procedure before installing the backing plate bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the backing plate bolts. Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 4. Install the park brake actuator. 5. Adjust the park brake shoe. 6. Adjust park brake cable. Disc Brake Splash Shield Replacement - Front 1500 Series Disc Brake Splash Shield Replacement - Front (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Remove the hub and bearing assembly. 2. Remove the splash shield. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11536 1. Install the splash shield. 2. Install the hub and bearing assembly. Replacement - Front 1500 Series Brake Rotor Replacement - Front (1500 Series) Tools Required ^ J41013 Rotor Resurfacing Kit ^ J42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable. 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Remove the tire and wheel assembly. 5. Mark the relationship of the rotor to the hub. 6. Compress the brake caliper pistons. 1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11537 2. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamps from the caliper. 7. Remove the brake caliper bracket bolts. 8. Notice: Refer to Brake Caliper Notice in Service Precautions. Remove the caliper and caliper bracket as an assembly. Support the caliper assembly with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 9. Remove the brake rotor retaining push nuts from the wheel studs, if necessary. 10. Remove the brake rotor screw. 11. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub. 12. Remove the rotor. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11538 4. Important: If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. Align the rotor to its original position on the hub (if applicable) and install the rotor. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the brake rotor screw. Tighten the screw to 12 Nm (106 inch lbs.). 6. If the rotor was removed and installed as part of a brake system repair, measure the assembled Lateral Runout (LRO) of the rotor to ensure optimum performance of the disc brakes. 7. If the rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. 8. Install the caliper and caliper bracket as a assembly. 9. Perform the following procedure before installing the caliper bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 10. Install the brake caliper bracket bolts. Tighten the bolts to 180 Nm (133 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the caliper pistons and pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11539 With RPO NYS Brake Rotor Replacement - Rear (1500 Series w/NYS, 25/3500 Series) Tools Required ^ J41013 Rotor Resurfacing Kit ^ J42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake, if necessary. 2. Inspect the fluid level in the brake master cylinder reservoir. 3. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 4. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 5. Remove the tire and wheel assembly. 6. Mark the relationship of the rotor to the hub. 7. Compress the brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. 8. Notice: Refer to Brake Caliper Notice in Service Precautions. Remove the brake caliper bracket bolts. 9. Remove the caliper and caliper bracket as an assembly. Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11540 10. Remove the brake rotor retaining push nuts from the wheel studs, if applicable. 11. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub. 12. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Align the rotor to its original position on the hub, if applicable. 5. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 6. If the rotor was removed and installed as part of a brake system repair, measure the assembled Lateral Runout (LRO) of the rotor to ensure optimum performance of the disc brakes. 7. If the rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. 8. Install the caliper and caliper bracket as an assembly. 9. Perform the following procedure before installing the brake caliper bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolts. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11541 Tighten the bolts to 300 Nm (221 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds then repeat steps 15-16 until a firm pedal is obtained. This will properly seat the caliper pistons and pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Without RPO NYS Brake Rotor Replacement - Rear (1500 Series w/o NYS) Tools Required ^ J2619-01 Slide Hammer With Adapter ^ J41013 Rotor Resurfacing Kit ^ J42450-A Wheel Hub Resurfacing Kit ^ J-46277 Rotor Removal Tool Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake, if necessary. 2. Inspect the fluid level in the brake master cylinder reservoir. 3. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 4. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 5. Remove the tire and wheel assembly. 6. Mark the relationship of the rotor to the hub. 7. Compress the brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11542 8. Remove the brake caliper bracket bolts. 9. Notice: Refer to Brake Caliper Notice in Service Precautions. Remove the caliper and caliper bracket as an assembly. Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 10. Remove the brake rotor retaining push nuts from the wheel studs, if applicable. 11. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub. 12. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11543 13. If the brake rotor cannot be removed, perform the following: 1. Assemble J-46277 to J2619-01. 2. Insert J-46277 between the rotor friction surfaces in the vent section of the rotor. DO NOT place the J-46277 on the rotor friction surface. 3. Using J-46277 and J2619-01 remove the rotor from the hub. 4. Inspect the park brake components for the following conditions: ^ Bent or broken hold down spring ^ Broken, cracked or worn brake shoe lining ^ Bent or damaged brake shoe ^ Worn, bent or damaged back plate 5. If any of these conditions are found replace the affected parts. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Align the rotor to its original position on the hub, if applicable, and install the rotor. 5. If the rotor was removed and installed as part of a brake system repair, measure the assembled Lateral Runout (LRO) of the rotor to ensure optimum performance of the disc brakes. 6. If the rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11544 7. Install the brake rotor by slowly turning the rotor while pushing the rotor towards the axle. 8. Install the caliper and caliper bracket as an assembly. 9. Perform the following procedure before installing the caliper bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket bolts. Tighten the bolts to 200 Nm (148 ft. lbs.). 11. Install the tire and wheel assembly. 12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 13. Slowly release the brake pedal. 14. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the caliper pistons and pads. 15. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Brake Rotor Refinishing Brake Rotor Refinishing Tools Required ^ J41013 Rotor Resurfacing Kit ^ J42450-A Wheel Hub Resurfacing Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 11545 Caution: Refer to Brake Dust Caution in Service Precautions. Important: ^ The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not refinish disc brake rotors in an attempt to correct the following conditions: Brake system noise - squeal, growl, groan - Uneven and/or premature disc brake pad wear - Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface - Scoring of the disc brake rotor friction surface less than the maximum allowable specification ^ Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: Thickness variation in excess of the maximum allowable specification - Excessive corrosion/rust and/or pitting - Cracks and/or heat spots - Excessive blueing discoloration - Scoring of the disc brake rotor surface in excess of the maximum allowable specification ^ Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification. 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Using the J42450-A , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J41013 , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 2. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled Lateral Runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair Backing Plate: Service and Repair Drum Brake Backing Plate Replacement Removal Procedure 1. Remove the park brake cable. Refer to one of the following procedures: ^ For the left park brake cable, refer to Park Brake Cable Replacement - Front in Park Brake. ^ For the right park brake cable, refer to Park Brake Cable Replacement - Left Rear (w/Rear Disc and w/o RPO NYS) Park Brake Cable Replacement - Left Rear (w/Rear Disc and w/RPO NYS) Park Brake Cable Replacement - Left Rear (w/Rear Drum) in Park Brake. 2. Remove the wheel cylinder. 3. Remove the rear axle shaft. 4. Remove the backing plate bolts. 5. Remove the backing plate. Installation Procedure 1. Position the backing plate on the rear axle housing. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backing plate bolts. Tighten the bolts to 135 Nm (100 ft. lbs.). 3. Install the rear axle shaft. 4. Install the wheel cylinder. 5. Install the park brake cable. Refer to one of the following procedures: ^ For the left park brake cable, refer to Park Brake Cable Replacement - Front in Park Brake. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Page 11550 ^ For the right park brake cable, refer to Park Brake Cable Replacement - Left Rear (w/Rear Disc and w/o RPO NYS) Park Brake Cable Replacement - Left Rear (w/Rear Disc and w/RPO NYS) Park Brake Cable Replacement - Left Rear (w/Rear Drum) in Park Brake. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rotor/Drum Refinishing Labor Operations Brake Drum: Technical Service Bulletins Brakes - Rotor/Drum Refinishing Labor Operations Bulletin No.: 06-05-22-007 Date: November 30, 2006 WARRANTY ADMINISTRATION Subject: Brake Rotor/Drum Refinishing Labor Operations Models: 2005-2007 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X (Canada Only) The purpose of this bulletin is to advise dealership personnel of labor operation changes relating to brake repairs. Existing brake rotor and drum labor operations have been revised to remove the refinishing times and new labor operations have been established for refinishing brake rotors or drums. The changes will become effective with the release of the December 2006 Labor Time Guide. The following changes: Applies to all 2005-2007 vehicles, unless 2005 was the last year of production for that particular model. May apply to 2004 and prior models years if the vehicle was produced after 2005 - e.g. TrailBlazer, Envoy, etc. Where the new labor operations for refinishing rotors or drums do not apply, the existing labor operations will still contain time for refinishing. Always refer to the Labor Time Guide for the appropriate labor operations and time for the vehicle being repaired. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rotor/Drum Refinishing Labor Operations > Page 11555 The list shown is of labor operations for brake service. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 11556 Brake Drum: Specifications Drum Brake Component Specifications Maximum Allowable Diameter ........................................................................................................................................................ 296.5 mm (11.673 inch) Maximum Allowable Radial Runout ................................................................................................................................................. 0.06 mm (0.0024 inch) Maximum Allowable Scoring .................................................................................. ................................................................................ 1.5 mm (0.06 inch) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Replacement Brake Drum: Service and Repair Replacement Brake Drum Replacement Removal Procedure Tools Required ^ J22364-01 Drum to Brake Shoe Clearance Gage ^ J42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. 1. Remove the rear tire and wheel. 2. Remove the rear brake drum retainer, if necessary. 3. Important: Before removing the brake drum, apply a small amount of penetrating oil around the wheel studs, axle shaft hub and brake drum. Remove the rear brake drum. 4. If the brake drum cannot be removed, perform the following. 1. Remove the rubber plug from the backing plate. 2. Insert a screwdriver (2), until contact has been made with the adjuster lever (4). 3. Slightly push the adjuster lever (4) away from the adjuster (1). 4. Using a second screwdriver (3,) rotate the adjuster (1) in a upward motion until the adjuster is seated. 5. Remove the brake drum. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Replacement > Page 11559 5. Using the J42450-A, clean the mating surface between the rear axle flange and brake drum. Installation Procedure 1. Using the J22364-01, measure the brake drum. 2. Using the J22364-01, adjust the rear brake shoes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Replacement > Page 11560 3. Install the rear brake drum. 4. Install the rear tire and wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Replacement > Page 11561 Brake Drum: Service and Repair Refinishing Brake Drum Refinishing Tools Required ^ J41013 Rotor Resurfacing Kit Important: DO NOT refinish the brake drums in order to correct any of the following complaints: ^ Brake noise (growl/squeal) ^ Premature brake lining wear ^ Cosmetic or superficial corrosion of the drum braking surface ^ Drum discoloration Refinish the brake drums ONLY when 1 or more of the following conditions exist: ^ Severe scoring of the drum braking surface (groove depth in excess of specification) ^ Brake pulsation caused by the following: Brake drum out of round (runout in excess of specification) - Corrosion or pitting that is deeper than the drum braking surface 1. Use a micrometer in order to measure the largest diameter of the brake drum. If the largest diameter of the brake drum exceeds the brake drum maximum refinish diameter, DO NOT refinish the brake drum. Replace the brake drum. 2. Use the J41013 or an equivalent tool in order to THOROUGHLY clean the rust from the brake drum flange. 3. Refinish the brake drum. 4. Important: Failure to obtain the best possible braking surface finish may cause the vehicle to stop with difficulty. After machining the brake drum, use 120 grit aluminum oxide sandpaper in order to create a non-directional braking surface. 5. Clean the braking surfaces with GM P/N 12377981 (Canadian P/N 10953463) or equivalent brake parts cleaner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 11566 Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Remove the rear brake shoes. 2. Disconnect the brake line from the wheel cylinder. 3. Plug or cap the brake line fitting as not to allow the brake fluid to become contaminated. 4. Remove the wheel cylinder bolts. 5. Remove the wheel cylinder. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 11567 1. Install the wheel cylinder. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel cylinder bolts. Tighten the bolts to 18 Nm (13 ft. lbs.). 3. Remove the plug or cap from the brake line fitting. 4. Connect the brake line to the wheel cylinder. Tighten the fitting to 19 Nm (14 ft. lbs.). 5. Install the rear brake shoes. 6. Bleed the brake system. 7. Check the master cylinder fluid level, add fluid if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice; When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11 GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. 10. With the ignition OFF, apply the brakes 3 - 5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11573 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3 - 5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11574 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 23. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11575 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Tools Required ^ J29532 Diaphragm Type Brake Pressure Bleeder, or equivalent ^ J35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3 - 5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J29532, or equivalent, to the J35589-A. 8. Charge the J29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11576 tightened. 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J35589-A. 23. Remove the J35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11577 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing HYDRAULIC BRAKE SYSTEM FLUSHING Caution: Brake fluid may irritate eyes and skin. In case of contact, take the following actions: * Eye contact--rinse thoroughly with water. * Skin contact--wash with soap and water. * If ingested--consult a physician immediately. Notice: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: » Fluid separation, indicating two types of fluid are present. A substance other than the recommended brake fluid has been introduced into the brake hydraulic system. - Swirled appearance--Oil-based substance - Layered appearance--Silicone-based substance » Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system. - Cloudy appearance--Moisture - Dark appearance/suspended particles in fluid--Dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 3.1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid. Refer to the procedures indicated. - Master Cylinder Replacement - Front Brake Hose Replacement - Rear Brake Hose Replacement - Front Brake Caliper Replacement - Rear Brake Caliper Replacement - Brake Pressure Modulator Valve Replacement 3.2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3.3. Dry the brake pipes using non-lubricated, filtered air. 3.4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated. - Master Cylinder Replacement - Also perform the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11578 - Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement . - Replace the brake master cylinder reservoir cap diaphragm. - Front Brake Hose Replacement - Rear Brake Hose Replacement - Front Brake Caliper Overhaul or Front Brake Caliper Replacement - Rear Brake Caliper Overhaul or Rear Brake Caliper Replacement - Brake Pressure Modulator Valve Replacement 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 11579 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11 (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Raise and support the vehicle. 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. 1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamps from the caliper. 7. Clean all dirt and foreign material from around the brake hose fitting. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. 8. Remove the brake hose to caliper bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11584 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the caliper or the brake hose end. 10. Remove the brake hose from the caliper. 11. Remove the brake caliper bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the caliper from the caliper bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11585 1. Install the caliper to the caliper bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. 4. Assemble 2 NEW copper brake hose gaskets to the brake hose bolt, and brake hose. 5. Install the brake hose to caliper bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11586 Tighten the bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11587 Brake Caliper: Service and Repair Brake Caliper Replacement - Rear W/O NYS Brake Caliper Replacement - Rear (1500 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Remove the tire and wheel assembly. 5. Compress the brake caliper piston. 1. Install a C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. 6. Clean all dirt and foreign material from the brake hose fitting. 7. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11588 Remove the brake hose to caliper bolt. 8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the caliper or the brake hose end. 9. Remove the brake hose from the caliper. 10. Remove the brake caliper bolts. 11. Remove the caliper from the caliper bracket. Installation Procedure 1. Important: Use denatured alcohol to clean the outside surface of caliper boot before installing new brake pads. If installing NEW brake pads, use a C-clamp in order to compress the piston to the bottom of the caliper bore. Use the old brake pad, a metal plate or a wooden block across the face of the piston in order to protect the piston and the caliper boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11589 2. Important: Use a small flat-bladed tool and lift the inner edge caliper boot next to the piston to release any trapped air. Ensure that the piston boot is below the level of the piston face. 3. Install the caliper to the caliper bracket. 4. Perform the following procedure before installing the brake caliper bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11590 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bolts. Tighten the bolts to 42 Nm (31 ft. lbs.). 6. Remove the rubber cap or plug from the exposed brake hose fitting end. 7. Important: Install 2 NEW copper brake hose gaskets. Assemble the 2 NEW copper brake hose gaskets to the brake hose bolt and brake hose. 8. Install the brake hose to caliper bolt. Tighten the bolt to 40 Nm (30 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. W/NYS Brake Caliper Replacement - Rear (1500 Series w/NYS, 25/3500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11591 before proceeding. 4. Remove the tire and wheel assembly. 5. Compress the brake caliper pistons. 1. Install a large C-clamp over the body of the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. 6. Clean all dirt and foreign material from the brake hose fitting. 7. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt. 8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the caliper or brake hose end. 9. Remove the brake hose from the caliper. 10. Loosen the brake caliper bolts. DO NOT remove. 11. Remove the brake caliper bracket bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the caliper and caliper bracket as an assembly. 13. Remove the brake caliper bolts. 14. Remove the caliper from the caliper bracket. 15. Inspect the caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11592 16. Remove the brake pads from the caliper bracket. 17. Remove the anti-rattle clips. 18. Inspect the caliper bracket for cracks and/or damage. Replace if necessary. 19. Inspect the caliper bracket bushings for damage and/or wear. Replace the bushings if necessary. 20. Perform the following procedure to replace the brake caliper bracket bushings. 1. Insert a flat-bladed tool between the bushing flange and the bracket. 2. Work the tool around the bushing flange and remove the bushing from the bracket. 3. Place a socket over the boot onto the bushing flange and install the bushing to the bracket. Installation Procedure 1. Install the anti-rattle clips to the caliper bracket. 2. Install the brake pads. 3. Install the caliper to the caliper bracket. 4. Perform the following procedure before installing the caliper bracket bolts and the caliper bolts: 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 5. Install the brake caliper bolts. DO NOT tighten. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11593 6. Install the caliper and caliper bracket as an assembly. 7. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket bolts. Tighten the bolts to 300 Nm (221 ft. lbs.). 8. Tighten the brake caliper bolts. Tighten the bolts to 108 Nm (80 ft. lbs.). 9. Remove the rubber cap or plug from the exposed brake hose fitting end. 10. Important: Install 2 NEW copper brake hose gaskets. Assemble the 2 NEW copper brake hose gaskets to the brake hose bolt and brake hose. 11. Install the brake hose to caliper bolt. Tighten the bolt to 40 Nm (30 ft. lbs.). 12. Bleed the hydraulic brake system. 13. Install the tire and wheel assembly. 14. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11594 Brake Caliper: Service and Repair Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear (1500 Series w/NYS, 25/3500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Disassembly Procedure Important: ^ Replace all the components included in the repair kits used to service this brake caliper. ^ Lubricate the rubber parts with clean brake fluid to make assembly easier. ^ The torque values specified are for dry, non lubricated fasteners. ^ Perform the service operations on a clean bench, free from all mineral oil materials. 1. Remove the brake caliper. 2. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Place a thin piece wood in front of the pistons in order to prevent damage. Remove the pistons by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the pistons. 4. Remove the piston boots. 5. Remove the piston seals. 6. Remove the caliper bleed screw cap. 7. Remove the caliper bleed screw. 8. Inspect the caliper bores and the piston seal grooves for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal areas replace the brake caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11595 9. Inspect the caliper bracket guide surfaces for corrosion and wear. Remove and replace the caliper bracket, if necessary. 10. Clean all of the residue from the brake pad guiding surfaces on the caliper and the caliper bracket. 11. Clean all the parts not included in the repair kit with denatured alcohol. 12. Dry all the parts with non lubricated filtered compressed air. 13. Blow out all passages in the caliper and the caliper bleeder valve. Assembly Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bleed screw. Tighten the screw to 12 Nm (106 inch lbs.). 2. Install the caliper bleed screw cap. 3. Lubricate the new piston seals and the brake caliper bore seal grooves with brake fluid. 4. Install NEW seals into the brake caliper bore seal grooves. 5. Ensure that the seals are not twisted. 6. Lubricate the caliper bores and the pistons with brake fluid. 7. Install the boots and pistons. 1. Install the boots over the end of the pistons so that the fold will face toward the brake caliper housing piston bore openings. 2. Seat the boost into the brake caliper bore grooves. Slide the pistons into the brake caliper bores. 3. Push down the pistons to the bottom of the brake caliper bores. 4. Ensure that the boots are properly seated into the piston grooves and into the grooves in the brake caliper bores. 8. Install the brake caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11596 Brake Caliper: Service and Repair Brake Caliper Bracket Replacement - Front Brake Caliper Bracket Replacement - Front (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Remove the tire and wheel assembly. 5. Compress the brake caliper pistons. 1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamps from the caliper. 6. Remove the brake caliper bolts. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11597 7. Notice: Refer to Brake Caliper Notice in Service Precautions. Remove the caliper from the caliper bracket. Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. 8. Remove the brake pads from the caliper bracket. 9. Remove the anti-rattle clips. 10. Remove the brake caliper bracket bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11598 11. Remove the brake caliper bracket. 12. Remove any contaminants or foreign material from the inside ends of the caliper bracket. 13. Clean the mounting surface and threads of the caliper bracket. Installation Procedure 1. Install the brake caliper bracket. 2. Perform the following procedure before installing the brake caliper bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11599 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket bolts. Tighten the bolts to 180 Nm (133 ft. lbs.). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads. 6. Slide the brake pads in until they contact the rotor. 7. Install the caliper to the caliper bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11600 8. Install the brake caliper bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). 9. Install the tire and wheel assembly. 10. Lower the vehicle. 11. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 12. Slowly release the brake pedal. 13. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the caliper pistons and pads. 14. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11601 Brake Caliper: Service and Repair Brake Caliper Bracket Replacement - Rear Brake Caliper Bracket Replacement - Rear (1500 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding. 3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding. 4. Remove the tire and wheel assembly. 5. Compress the brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. 6. Remove the brake caliper bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11602 7. Notice: Refer to Brake Caliper Notice in Service Precautions. Remove the caliper from the caliper bracket. Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. 8. Remove the brake pads from the caliper bracket. 9. Remove the anti-rattle clips. 10. Remove the brake caliper bracket bolts. 11. Remove the brake caliper bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11603 12. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 13. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure 1. Install the brake caliper bracket. 2. Perform the following procedure before installing the brake caliper bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket bolts. Tighten the bolts to 200 Nm (148 ft. lbs.). 4. Install the anti rattle clips to the brake caliper bracket. 5. Install the brake pads. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 11604 6. Install the caliper to the caliper bracket. 7. Install the brake caliper bolts. Tighten the bolts to 42 Nm (31 ft. lbs.). 8. Install the tire and wheel assembly. 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the caliper pistons and pads. 12. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not provided by the vehicle manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 11609 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Brake Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 11613 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Using needle nose pliers, compress the locking tabs at the opposite side of the master cylinder. 3. Remove the fluid level sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 11614 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Brake Pressure Differential Switch With RPO JC4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Caution: Always use double-walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and in the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and brake system resulting in personal injury. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: Brake pipes that run parallel to each other must maintain a 6 mm (1/4 inch) clearance. 1. Disconnect the brake pipe fittings. 2. Remove the brake pipe fasteners from the vehicle. 3. Remove the brake pipe from the vehicle. Installation Procedure 1. Bend the brake pipe to achieve proper fit. 2. Install the brake pipe to the vehicle. Maintain a clearance of 19 mm (3/4 inch) for all moving or vibrating components. 3. Install the brake pipe fasteners to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Connect the brake pipe fittings. ^ Tighten the brake pipe fittings to the Brake Pressure Modulator Valve (BPMV) or the wheel jounce hoses to 25 Nm (18 ft. lbs.). ^ Tighten the brake pipe fittings to the master cylinder to 25 Nm (18 ft. lbs.). 5. Bleed the hydraulic brake system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 11622 Brake Hose/Line: Service and Repair Brake Hose Replacement - Front Brake Hose Replacement - Front Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Raise and suitably support the vehicle. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose and brake pipe fittings. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end. 5. Remove the brake hose retaining clip from the hose mounting bracket. 6. Remove the brake hose bolt and the bracket from the upper control arm. 7. Remove the brake hose bolt and the bracket from the steering knuckle. 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove the brake hose from the brake caliper. 10. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 11623 1. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets, and the brake hose bolt to the brake hose. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake hose to caliper bolt and 2 new washers to the brake caliper. Tighten the bolt to 40 Nm (30 ft. lbs.). 3. Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. With the weight of the vehicle on the suspension, install the brake hose into the bracket. 4. Install the brake hose bolt and the bracket to the steering knuckle. Tighten the bolt to 9 Nm (80 inch lbs.). 5. Install the brake hose bolt and the bracket to the upper control arm. Tighten the bolt to 9 Nm (80 inch lbs.). 6. Install the brake hose retaining clip. 7. Remove the rubber cap or plug from the exposed brake pipe fitting end. 8. Connect the brake pipe fitting nut to the brake hose: ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or the pipe. Tighten the bolt to 25 Nm (18 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Ensure that the hose does not make contact with any part of the suspension or the wheel. Check the hose in extreme right and left turn conditions. If the hose makes contact, remove the hose and correct the condition. 12. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 11624 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear (Caliper) Brake Hose Replacement - Rear (Caliper) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Raise and suitably support the vehicle. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose and brake pipe fittings. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Use a backup wrench on the hose fitting end (1), disconnect the brake pipe fitting (2) from the brake hose (1), then cap or plug the brake pipe fitting end. 5. Remove the brake hose retaining clip (3) from the hose mounting bracket. 6. Remove the brake hose (1) from the mounting bracket. 7. Remove the brake hose to caliper bolt from the brake caliper. 8. Remove the brake hose from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 11625 1. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose bolt to the brake hose. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake hose to caliper bolt and 2 new washers to the brake caliper. Tighten the bolt to 40 Nm (30 ft. lbs.). 3. Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. Install the brake hose (1) into the brake hose bracket. 4. Install the brake hose retaining clip (3). 5. Remove the rubber cap or plug from the exposed brake pipe fitting end. 6. Connect the brake pipe fitting nut (2) to the brake hose (1): ^ Use a backup wrench on the hose fitting (1). ^ Do not bend the bracket or the pipe. Tighten the brake pipe fitting end (2) to 25 Nm (18 ft. lbs.). 7. Bleed the hydraulic brake system. 8. Install the tire and wheel assembly. 9. Ensure that the hose does not make contact with any part of the suspension or the wheel. If the hose makes contact remove the hose and correct the condition. 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 11626 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear (Jounce) Brake Hose Replacement - Rear (Jounce) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Raise and support the vehicle. 2. Clean all dirt and foreign material from the brake hose and brake pipe fittings. 3. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end. 4. Remove the brake hose retaining clip from the hose mounting bracket. 5. Remove the jounce hose from the bracket. 6. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Disconnect the rear brake pipes from the junction block on the rear axle and cap or plug the brake pipe fitting ends. 7. Remove the junction block retaining bolt from the axle. 8. Remove the brake hose from the vehicle. Installation Procedure 1. Install the rear brake hose 2. Notice: Refer to Fastener Notice in Service Precautions. Install the junction block retaining bolt to the axle. Tighten the bolt to 22 Nm (16 ft. lbs.). 3. Uncap or unplug the rear brake pipes and connect the pipes to the junction block on the axle. Tighten the fitting to 25 Nm (18 ft. lbs.). 4. Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 11627 Install the brake hose into the bracket. 5. Install the jounce hose retaining clip. 6. Remove the rubber cap or plug from the exposed brake pipe fitting end. 7. Connect the brake pipe fitting nut to the brake hose: ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or the pipe. Tighten the fitting to 25 Nm (18 ft. lbs.). 8. Ensure that the hose does not make contact with any part of the suspension. If the hose makes contact remove the hose and correct the condition. 9. Bleed the hydraulic brake system. 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair Brake Proportioning/Combination Valve: Service and Repair Combination Valve Replacement Removal Procedure Important: Note the identification code on the combination valve. The new valve must have the same identification number as the old valve. 1. Remove the combination valve electrical connector. 2. Remove the front and the rear brake pipes. 3. Remove the combination valve from the vehicle. Installation Procedure Important: Verify that the replacement combination valve has the same pin punched identification code as the code on the old combination valve. 1. Install the combination valve to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the front and the rear brake pipes to the combination valve. Tighten the brake pipe nuts to 25 Nm (18 ft. lbs.). 3. Connect the combination valve electrical connector. 4. Important: Verify that the combination valve metering rod is depressed during bleeding. Bleed the brake system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Remove the negative battery cable. 2. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 3. Disconnect the chassis electrical harness connectors from the EBCM. 4. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. Disconnect 5 brake lines from the BPMV. 5. Remove the bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 6. Remove the EHCU assembly (1) from the vehicle. 7. Remove the bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). 8. Disconnect the 2 way ABS pump motor connector. 9. Remove the bolts (1) from the EBCM (2). 10. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. 11. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 11634 Installation Procedure 1. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Install the EBCM (2) onto BPMV (3). 2. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. Install the four EBCM bolts. Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM. 4. Install the BPMV (3) to BPMV bracket (5). 5. Install the BPMV to bracket retaining bolts (4). Tighten the bolts to 9 Nm (7 ft. lbs.). 6. Install the EHCU assembly (1, 2) to the vehicle frame (5). Tighten the three EHCU bracket bolts (4) to 25 Nm (18 ft. lbs.). 7. Connect the chassis electrical harness connectors to the EBCM (1). 8. Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. Install the 5 brake pipes to the BPMV (6). Tighten the brake pipe fittings to 25 Nm (18 ft. lbs.). 9. Connect negative battery cable. 10. Bleed the brake system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Vacuum Boost) Master Cylinder Replacement (Vacuum Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Disconnect the brake pipes from the master cylinder. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11639 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. Tighten the fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11640 Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Hydraulic Boost) Master Cylinder Replacement (Hydraulic Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Disconnect the brake pipes from the master cylinder. 4. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11641 2. Bench bleed the master cylinder. 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. Tighten the pipe fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11642 Brake Master Cylinder: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11 (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11643 Brake Master Cylinder: Service and Repair Master Cylinder Fluid Level Sensor Replacement Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Using needle nose pliers, compress the locking tabs at the opposite side of the master cylinder. 3. Remove the fluid level sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11644 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11645 Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Vacuum Boost) Master Cylinder Replacement (Vacuum Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Disconnect the brake pipes from the master cylinder. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11646 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. Tighten the fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Master Cylinder Replacement (Hydraulic Boost) Master Cylinder Replacement (Hydraulic Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11647 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Disconnect the brake pipes from the master cylinder. 4. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. Tighten the pipe fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11648 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11 (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Master Cylinder Fluid Level Sensor Replacement Master Cylinder Fluid Level Sensor Replacement Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11649 1. Disconnect the electrical connector from the fluid level sensor. 2. Using needle nose pliers, compress the locking tabs at the opposite side of the master cylinder. 3. Remove the fluid level sensor. Installation Procedure 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11650 Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Remove the master cylinder. 3. Drain the master cylinder reservoir. 4. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange. 5. Remove the brake fluid level sensor by carefully depressing the retaining tabs and pushing the sensor through the reservoir. Carefully remove the reservoir retaining pins. 6. Remove the reservoir from the master cylinder by pulling the reservoir straight up and away from the cylinder. 7. Remove the seals from the master cylinder. Installation Procedure 1. Inspect the reservoir for cracks or deformation. If found, replace the reservoir. 2. Clean the reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 11651 4. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11 (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Install the lubricated seals, make sure they are fully seated. 6. Install the reservoir to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned. 7. Carefully install the reservoir retaining pins to secure the reservoir. 8. Place the brake fluid level sensor into the reservoir, press into place to secure the sensor retaining tabs. 9. Remove the master cylinder from the vice. 10. Install the master cylinder. 11. Release the park brake. 12. Bleed the hydraulic brake system. Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 11656 Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Remove the rear brake shoes. 2. Disconnect the brake line from the wheel cylinder. 3. Plug or cap the brake line fitting as not to allow the brake fluid to become contaminated. 4. Remove the wheel cylinder bolts. 5. Remove the wheel cylinder. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 11657 1. Install the wheel cylinder. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel cylinder bolts. Tighten the bolts to 18 Nm (13 ft. lbs.). 3. Remove the plug or cap from the brake line fitting. 4. Connect the brake line to the wheel cylinder. Tighten the fitting to 19 Nm (14 ft. lbs.). 5. Install the rear brake shoes. 6. Bleed the brake system. 7. Check the master cylinder fluid level, add fluid if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair Parking Brake Actuator: Service and Repair Park Brake Actuator Replacement (1500 Series w/Rear Disc) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cables from the equalizer by pulling down on the intermediate cable and release the rear cables from the equalizer bar. 5. Remove the rear park brake cable from the park brake actuator lever. 6. For vehicles without RPO NYS, remove the park brake cable from the mounting bracket by depressing the locking tabs. 7. For vehicles with RPO NYS, remove the rear park brake bracket bolt. 8. Remove the rotor. 9. Remove the axle shaft. 10. Remove the park brake shoe. 11. Remove the backing plate bolts. 12. Remove the park brake actuator lever housing from the backing plate. Installation Procedure 1. Install the park brake actuator lever housing to the backing plate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair > Page 11662 2. Perform the following procedure before installing the backing plate bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Install the backing plate bolts. Tighten the bolts to the following: ^ 15 Series, 25 Series w/6.0L, tighten the bolts to 135 Nm (100 ft. lbs.). ^ 25 Series w/8.1L or 6.6L, 35 Series, tighten the bolts a first pass to 160 Nm (118 ft. lbs.). ^ 25 Series w/8.1L or 6.6L, 35 Series, tighten the bolts a final pass an additional 30 degrees. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the park brake shoe. 5. Install the axle shaft. 6. Adjust the park brake shoe. 7. Install the rotor. 8. For vehicles without RPO NYS, install the park brake cable to the mounting bracket until the locking tabs snap into place. 9. For vehicles with RPO NYS, install the rear park brake bracket bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). 10. Install the rear park brake cable to the park brake actuator lever. 11. Install the rear cables to the equalizer by pulling down on the intermediate cable and install the rear cables to the equalizer bar. 12. Install the tire and wheel assembly. 13. Remove the safety stands. 14. Lower vehicle. 15. Adjust park brake cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front Parking Brake Cable: Service and Repair Replacement - Front Park Brake Cable Replacement - Front Removal Procedure 1. Release the park brake. 2. Remove the park brake pedal. 3. Roll the carpet back to access cable grommet. 4. Raise and support the vehicle. 5. Disengage the grommet and the cable from the floor pan. 6. Disconnect the front cable from the intermediate cable. 7. Remove the cable from the body mount by depressing the retaining tabs. 8. Remove the cable. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11667 1. Install the cable. 2. Snap the retainer tabs into the body mount. 3. Connect the front cable to the intermediate cable. 4. Route the cable in through the floor pan and engage the grommet. 5. Remove the safety stands. 6. Lower the vehicle. 7. Roll the carpet into place. 8. Install the park brake pedal. 9. Adjust the park brake system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11668 Parking Brake Cable: Service and Repair Replacement - Intermediate w/Rear Disc Park Brake Cable Replacement - Intermediate (w/Rear Disc) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer then removing the cables from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. 5. For 25/35 series vehicles, disconnect the intermediate cable from the rear park brake cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11669 6. Disconnect the intermediate cable from the front cable. 7. Remove the intermediate cable from the vehicle. Installation Procedure 1. Install the intermediate cable to the vehicle. 2. Connect the intermediate cable to the front cable. 3. For 25/35 series vehicles, connect the intermediate cable to the rear park brake cable. 4. For 15 series vehicles, install the rear park brake cables to the equalizer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11670 5. For 15 series vehicles, install the equalizer and the nut to the threaded end of the intermediate cable. Tighten the nut to 3.5 Nm (31 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. For 25/35 series vehicles, enable the park brake cable automatic adjuster. 7. Remove the safety stands and lower the vehicle. 8. Adjust the park brake system. w/Rear Drum Park Brake Cable Replacement - Intermediate (w/Rear Drum) Removal Procedure 1. Ensure that the park brake is released. 2. Raise and support the vehicle. 3. Relieve tension on the park brake cables by pulling down on the front park brake cable (1) just in front of the equalizer. 4. Remove the park brake cables (2, 3) from the equalizer bar. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11671 5. Disconnect the intermediate cable from the front cable. 6. Remove the intermediate cable from the vehicle. Installation Procedure 1. Install the intermediate cable to the vehicle. 2. Connect the intermediate cable to the front cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11672 3. Install the park brake cables (2, 3) to the equalizer. 4. Lower the vehicle. 5. Adjust the park brakes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11673 Parking Brake Cable: Service and Repair Replacement - Left Rear w/Rear Disc and w/o RPO NYS Park Brake Cable Replacement - Left Rear (w/Rear Disc and w/o RPO NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. 5. For 25/35 series vehicles, disconnect the cable at the equalizer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11674 6. Remove the cable from the mounting bracket by depressing the locking tabs. 7. Remove the cable at the shock absorber bracket by removing the bolt. 8. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 9. Remove the park brake cable (2) from the lever (1). 10. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11675 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the cable at the shock absorber bracket and install the bolt. Tighten the bolt to 22 Nm (16 ft. lbs.). 5. Install the cable to the mounting bracket until the locking tabs snap into place. 6. For 25/35 series vehicles, connect the cable at the equalizer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11676 7. For 25/35 series vehicles, enable the park brake cable automatic adjuster. 8. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Remove the safety stands and lower the vehicle. 11. Adjust the park brake cable. w/Rear Disc and w/RPO NYS Park Brake Cable Replacement - Left Rear (w/Rear Disc and w/RPO NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11677 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the cable at the lower shock absorber mount by removing the bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11678 6. Remove the rear cable mounting bracket bolt. 7. Remove the cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the cable from the guides and the body mounts. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11679 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. 2. Install the park brake cable to the lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable and the bolt to the lower shock absorber mount. Tighten the bolt to 22 Nm (16 ft. lbs.). 5. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11680 6. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 7. Remove the safety stands. 8. Lower the vehicle. w/Rear Drum Park Brake Cable Replacement - Left Rear (w/Rear Drum) Tools Required ^ J37043 Park Brake Cable Release Tool Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Ensure that the park brake is released. 2. Raise and support the vehicle. 3. Relieve tension on the park brake cables by pulling down on the front park brake cable (1) just in front of the equalizer. 4. Remove the left rear park brake cable (3) from the equalizer bar. 5. Remove the park brake cable from the frame bracket and guides. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11681 6. Remove the rear brake shoes. 7. Using the J37043 (1), remove the park brake cable from the backing plate. 8. Remove the park brake cable from the vehicle. Installation Procedure 1. Install the park brake cable into the backing plate. 2. Install the rear brake shoes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11682 3. Install the park brake cable through the frame bracket and guides. 4. Install the left rear park brake cable (3) to the equalizer bar. 5. Lower the vehicle. 6. Adjust the park brake. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11683 Parking Brake Cable: Service and Repair Replacement - Right Rear w/Rear Disc w/o RPO NYS Park Brake Cable Replacement - Right Rear (w/Rear Disc w/o RPO NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. 3. Release the park brake. 4. Raise and support the vehicle. 5. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 6. For 25/35 series vehicles, disable the park brake cable automatic adjuster. 7. For 25/35 series vehicles, disconnect the cable at the equalizer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11684 8. Remove the bolt from the rear axle clip. 9. Remove the cable from the differential clip. 10. Remove the cable from the mounting bracket by depressing the locking tabs. 11. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 12. Remove the park brake cable (2) from the lever (1). 13. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11685 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Install the cable to the mounting bracket until the locking tabs snap into place. 5. Notice: Refer to Fastener Notice in Service Precautions. Bolt the cable to the differential clips. Tighten the bolt to 22 Nm (16 ft. lbs.). 6. Important: After installing the cable to the rear axle holding clip, verify that clip is securely retaining the cable. If not, crimp the clip by hand taking care not to pinch or kink the cable. Install the cable to the differential clip. 7. For 25/35 series vehicles, connect the cable at the equalizer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11686 8. For 25/35 series vehicles, enable the park brake cable automatic adjuster. 9. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 10. Remove the safety stands. 11. Remove the safety stands and lower the vehicle. 12. Adjust the park brake cable. w/Rear Disc w/RPO NYS Park Brake Cable Replacement - Right Rear (w/Rear Disc w/RPO NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11687 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the park brake cable from the differential clip. Remove the bolt retaining the park brake cable from the rear axle clip. 6. Remove the rear brake cable mounting bracket bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11688 7. Remove the brake cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the brake cable from the guides and the body mounts. Installation Procedure 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. 2. Install the park brake cable to the lever. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11689 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable to the differential clip. 5. Install the park brake cable bolt to the rear axle clip. Tighten the bolt to 22 Nm (16 ft. lbs.). 6. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 7. Install the park brake cable into the mounting bracket until the locking tabs snap into place. 8. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11690 w/Rear Drum Park Brake Cable Replacement - Right Rear (w/Rear Drum) Tools Required ^ J37043 Park Brake Cable Release Tool Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Ensure that the park brake is released. 2. Raise the vehicle. 3. Relieve tension on the park brake cables by pulling down on the front park brake cable (1) just in front of the equalizer. 4. Remove the right park brake cable (2) from the equalizer. 5. Remove the park brake cable from the frame bracket and guides. 6. Remove the cable clip bolt (1) at the rear axle housing. 7. Remove the right cable (3) from the clip on top of the rear axle housing. 8. Remove the rear brakes shoes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11691 9. Using the J37043 (1), remove the park brake cable. 10. Remove the park brake cable from the vehicle. Installation Procedure 1. Install the park brake cable to the backing plate. 2. Install the rear brakes shoes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11692 3. Position the cable clip (2) to the rear axle housing. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the cable clip bolt (1). Tighten the bolt to 22 Nm (16 ft. lbs.). 5. Install the right cable (3) over the clip on top of the rear axle housing. 6. Install the park brake cable through the frame bracket and guides. 7. Install the right park brake cable (2) to the equalizer. 8. Lower the vehicle. 9. Adjust the park brakes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11693 Parking Brake Cable: Service and Repair Replacement - Front Park Brake Cable Replacement - Front Removal Procedure 1. Release the park brake. 2. Remove the park brake pedal. 3. Roll the carpet back to access cable grommet. 4. Raise and support the vehicle. 5. Disengage the grommet and the cable from the floor pan. 6. Disconnect the front cable from the intermediate cable. 7. Remove the cable from the body mount by depressing the retaining tabs. 8. Remove the cable. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11694 1. Install the cable. 2. Snap the retainer tabs into the body mount. 3. Connect the front cable to the intermediate cable. 4. Route the cable in through the floor pan and engage the grommet. 5. Remove the safety stands. 6. Lower the vehicle. 7. Roll the carpet into place. 8. Install the park brake pedal. 9. Adjust the park brake system. w/Rear Disc Park Brake Cable Replacement - Intermediate (w/Rear Disc) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11695 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer then removing the cables from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. 5. For 25/35 series vehicles, disconnect the intermediate cable from the rear park brake cable. 6. Disconnect the intermediate cable from the front cable. 7. Remove the intermediate cable from the vehicle. Installation Procedure 1. Install the intermediate cable to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11696 2. Connect the intermediate cable to the front cable. 3. For 25/35 series vehicles, connect the intermediate cable to the rear park brake cable. 4. For 15 series vehicles, install the rear park brake cables to the equalizer. 5. For 15 series vehicles, install the equalizer and the nut to the threaded end of the intermediate cable. Tighten the nut to 3.5 Nm (31 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. For 25/35 series vehicles, enable the park brake cable automatic adjuster. 7. Remove the safety stands and lower the vehicle. 8. Adjust the park brake system. w/Rear Drum Park Brake Cable Replacement - Intermediate (w/Rear Drum) Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11697 1. Ensure that the park brake is released. 2. Raise and support the vehicle. 3. Relieve tension on the park brake cables by pulling down on the front park brake cable (1) just in front of the equalizer. 4. Remove the park brake cables (2, 3) from the equalizer bar. 5. Disconnect the intermediate cable from the front cable. 6. Remove the intermediate cable from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11698 1. Install the intermediate cable to the vehicle. 2. Connect the intermediate cable to the front cable. 3. Install the park brake cables (2, 3) to the equalizer. 4. Lower the vehicle. 5. Adjust the park brakes. w/Rear Disc and w/o RPO NYS Park Brake Cable Replacement - Left Rear (w/Rear Disc and w/o RPO NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11699 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. 5. For 25/35 series vehicles, disconnect the cable at the equalizer. 6. Remove the cable from the mounting bracket by depressing the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11700 7. Remove the cable at the shock absorber bracket by removing the bolt. 8. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 9. Remove the park brake cable (2) from the lever (1). 10. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11701 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the cable at the shock absorber bracket and install the bolt. Tighten the bolt to 22 Nm (16 ft. lbs.). 5. Install the cable to the mounting bracket until the locking tabs snap into place. 6. For 25/35 series vehicles, connect the cable at the equalizer. 7. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11702 8. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Remove the safety stands and lower the vehicle. 11. Adjust the park brake cable. w/Rear Disc and w/RPO NYS Park Brake Cable Replacement - Left Rear (w/Rear Disc and w/RPO NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11703 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the cable at the lower shock absorber mount by removing the bolt. 6. Remove the rear cable mounting bracket bolt. 7. Remove the cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11704 9. Remove the cable from the guides and the body mounts. Installation Procedure 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. 2. Install the park brake cable to the lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11705 4. Install the park brake cable and the bolt to the lower shock absorber mount. Tighten the bolt to 22 Nm (16 ft. lbs.). 5. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 6. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 7. Remove the safety stands. 8. Lower the vehicle. w/Rear Drum Park Brake Cable Replacement - Left Rear (w/Rear Drum) Tools Required ^ J37043 Park Brake Cable Release Tool Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11706 Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Ensure that the park brake is released. 2. Raise and support the vehicle. 3. Relieve tension on the park brake cables by pulling down on the front park brake cable (1) just in front of the equalizer. 4. Remove the left rear park brake cable (3) from the equalizer bar. 5. Remove the park brake cable from the frame bracket and guides. 6. Remove the rear brake shoes. 7. Using the J37043 (1), remove the park brake cable from the backing plate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11707 8. Remove the park brake cable from the vehicle. Installation Procedure 1. Install the park brake cable into the backing plate. 2. Install the rear brake shoes. 3. Install the park brake cable through the frame bracket and guides. 4. Install the left rear park brake cable (3) to the equalizer bar. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11708 6. Adjust the park brake. w/Rear Disc w/o RPO NYS Park Brake Cable Replacement - Right Rear (w/Rear Disc w/o RPO NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. 3. Release the park brake. 4. Raise and support the vehicle. 5. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 6. For 25/35 series vehicles, disable the park brake cable automatic adjuster. 7. For 25/35 series vehicles, disconnect the cable at the equalizer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11709 8. Remove the bolt from the rear axle clip. 9. Remove the cable from the differential clip. 10. Remove the cable from the mounting bracket by depressing the locking tabs. 11. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 12. Remove the park brake cable (2) from the lever (1). 13. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11710 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Install the cable to the mounting bracket until the locking tabs snap into place. 5. Notice: Refer to Fastener Notice in Service Precautions. Bolt the cable to the differential clips. Tighten the bolt to 22 Nm (16 ft. lbs.). 6. Important: After installing the cable to the rear axle holding clip, verify that clip is securely retaining the cable. If not, crimp the clip by hand taking care not to pinch or kink the cable. Install the cable to the differential clip. 7. For 25/35 series vehicles, connect the cable at the equalizer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11711 8. For 25/35 series vehicles, enable the park brake cable automatic adjuster. 9. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 10. Remove the safety stands. 11. Remove the safety stands and lower the vehicle. 12. Adjust the park brake cable. w/Rear Disc w/RPO NYS Park Brake Cable Replacement - Right Rear (w/Rear Disc w/RPO NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11712 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the park brake cable from the differential clip. Remove the bolt retaining the park brake cable from the rear axle clip. 6. Remove the rear brake cable mounting bracket bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11713 7. Remove the brake cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the brake cable from the guides and the body mounts. Installation Procedure 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. 2. Install the park brake cable to the lever. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11714 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable to the differential clip. 5. Install the park brake cable bolt to the rear axle clip. Tighten the bolt to 22 Nm (16 ft. lbs.). 6. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 7. Install the park brake cable into the mounting bracket until the locking tabs snap into place. 8. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11715 w/Rear Drum Park Brake Cable Replacement - Right Rear (w/Rear Drum) Tools Required ^ J37043 Park Brake Cable Release Tool Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Ensure that the park brake is released. 2. Raise the vehicle. 3. Relieve tension on the park brake cables by pulling down on the front park brake cable (1) just in front of the equalizer. 4. Remove the right park brake cable (2) from the equalizer. 5. Remove the park brake cable from the frame bracket and guides. 6. Remove the cable clip bolt (1) at the rear axle housing. 7. Remove the right cable (3) from the clip on top of the rear axle housing. 8. Remove the rear brakes shoes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11716 9. Using the J37043 (1), remove the park brake cable. 10. Remove the park brake cable from the vehicle. Installation Procedure 1. Install the park brake cable to the backing plate. 2. Install the rear brakes shoes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11717 3. Position the cable clip (2) to the rear axle housing. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the cable clip bolt (1). Tighten the bolt to 22 Nm (16 ft. lbs.). 5. Install the right cable (3) over the clip on top of the rear axle housing. 6. Install the park brake cable through the frame bracket and guides. 7. Install the right park brake cable (2) to the equalizer. 8. Lower the vehicle. 9. Adjust the park brakes. Equalizer Replacement Park Brake Cable Equalizer Replacement (w/Rear Disc) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11718 3. For the 15 series vehicles, remove the nut from the threaded end of the intermediate cable. 4. Disconnect the equalizer from the rear park brake cables. 5. For 25/35 series vehicles, disable the park brake cable automatic adjuster. 6. For 25/35 series vehicles, disconnect the cable at the equalizer. Installation Procedure 1. For 25/35 series vehicles, connect the cable at the equalizer. 2. For 25/35 series vehicles, enable the park brake cable automatic adjuster. 3. For the 15 series vehicles, connect the rear park brake cables to the equalizer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11719 4. For the 15 series vehicles, install the nut to the threaded end of the intermediate cable. Tighten the nut to 3.5 Nm (31 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Remove the safety stands and lower the vehicle. 6. Adjust the park brake system. Mounting Bracket Replacement Park Brake Cable Mounting Bracket Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. 3. Release the tension on the cables by loosening the nut at the equalizer. 4. Disconnect the rear cables from the equalizer. 5. Remove the rear cables from the mounting bracket by depressing the retaining tabs and pulling rearward. 6. Remove the cable support bracket nuts. 7. Remove the cable support bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11720 1. Install the cable support bracket. 2. Install the cable support bracket nuts. Tighten the support bracket nuts to 85 Nm (64 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear cables to the mounting bracket by inserting the cable till all the retaining tabs snap into place. 4. Connect the rear cables to the equalizer. 5. Tighten the nut to the intermediate cable at the equalizer. Tighten the nut to 3.5 Nm (31 inch lbs.). 6. Remove the safety stands. 7. Lower the vehicle. Guide Replacement Park Brake Cable Guide Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake guide from the park brake cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Replacement - Front > Page 11721 Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. 3. Install the park brake cable guide bolt to the frame. Tighten the bolt to 18 Nm (13 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair Park Brake Release Handle Assembly Replacement Removal Procedure 1. Disconnect the negative battery cable. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the park brake release lever mounting bolt. 3. Remove the park brake release lever handle from the knee bolster. 4. Remove the MID-bussed electrical center from the bracket. 5. Remove the park brake release cable housing from the pedal assembly. 6. Remove the park brake release cable from the pedal assembly. 7. Note the routing of the cable as you remove the park brake release handle assembly from the vehicle. Installation Procedure 1. Install the park brake release handle assembly to the vehicle. Install the cable using the same routing as the original cable. 2. Install the park brake release cable to the pedal assembly. 3. Install the park brake release cable housing to the pedal assembly. 4. Install the MID-bussed electrical center to the bracket. 5. Install the park brake release lever handle to the knee bolster. 6. Install the park brake release lever handle bolt. Tighten the bolt to 9 Nm (80 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 7. Connect the negative battery cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair Parking Brake Pedal: Service and Repair Park Brake Pedal Assembly Replacement Removal Procedure 1. Disconnect the negative battery cable. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Raise and support the vehicle. 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer then removing the cables from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. 5. Remove the safety stands and lower the vehicle. 6. Remove the left side hinge pillar panel. 7. Remove the MID-bussed electrical center from the bracket. 8. Disconnect the park brake warning lamp connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Page 11728 9. Remove the park brake release handle bolts. 10. Remove the park brake lever mounting nuts. 11. Disconnect the front park brake cable from the park brake lever. 12. Remove the park brake lever. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Page 11729 1. Connect the front park brake cable to the park brake lever. 2. Install the park brake lever. 3. Install the park brake lever mounting nuts. Tighten the nuts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Install he park brake release handle bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Page 11730 5. Connect the park brake warning lamp connector. 6. Install the MID-bussed electrical center to the bracket. 7. Install the left side hinge pillar panel. 8. Raise and support the vehicle. 9. For 15 series vehicles, install the park brake cable to the equalizer by pulling down on the park brake cable in front of the equalizer then installing the cable to the equalizer bar. 10. For 25/35 series vehicles, enable the park brake cable automatic adjuster. 11. Remove the safety stands and lower the vehicle. 12. Connect the negative battery cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair Park Brake Shoe Replacement (w/RPO NYS) Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. 1. Release the park brake. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cable by pulling down on the intermediate cable then release the cable from the equalizer bar. 5. Remove the rear park brake bracket bolt. 6. Remove the park brake cable from the park brake actuator lever. 7. Remove the wheel bearing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 11734 8. Remove the park brake shoe from the backing plate. Installation Procedure 1. Install the park brake shoe to the backing plate. 2. Install the wheel bearing. 3. Adjust the park brake shoe. 4. Install the park brake cable to the park brake actuator lever. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake bracket bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). 6. Install the park brake cable to the equalizer bar. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Adjust the park brake cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Service and Repair Parking Brake Warning Lamp: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. Caution: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Service and Repair > Page 11738 1. Install the park brake warning lamp switch. 2. Install the park brake warning lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Park Brake Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11751 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11752 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11753 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11754 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11755 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11756 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11757 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11758 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11759 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11760 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11761 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11762 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11763 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11764 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11770 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11771 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11772 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11773 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11774 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11775 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11776 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11777 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11778 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11779 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11780 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11781 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11782 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11783 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Hydraulic Brake Booster Accumulator Replacement Hydraulic Brake Booster: Service and Repair Hydraulic Brake Booster Accumulator Replacement Hydraulic Brake Booster Accumulator Replacement Tools Required ^ J26889 Accumulator Piston Compressor Removal Procedure Caution: The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or personal injury may result. Do not apply heat to accumulator. Do not attempt to repair an inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 inch) diameter hole through the end of the accumulator can, opposite the O-ring. Caution: Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. 1. Apply the park brake and block the wheels. 2. Depress brake pedal at least 10 times in order to relieve pressure in the accumulator. 3. Remove the master cylinder from the hydraulic booster. 4. Place the J26889 over the end of the accumulator. 5. Install the nut on the stud. 6. Depress the accumulator with a C-clamp. If the accumulator does not move with moderate pressure, remove the C-clamp and depress the brake pedal ten times in order to relieve pressure in the accumulator. 7. Rotate the retaining ring (2) until either end of the ring is under the access hole (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Hydraulic Brake Booster Accumulator Replacement > Page 11786 8. Depress and hold the retaining ring (2) with a small tool inserted into the access hole (1). 9. Remove the accumulator retainer ring (1) using a small hook shaped tool. 10. Release the C-clamp. 11. Remove the nut from the stud. 12. Remove the J26889. 13. Remove the accumulator (2) and the O-ring seal (3). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Hydraulic Brake Booster Accumulator Replacement > Page 11787 1. Lubricate all of the seals and the metal friction points with power steering fluid. 2. Install the accumulator (2) and the O-ring seal (3). 3. Place the J26889 over the end of the accumulator. 4. Install the nut on the stud. 5. Depress the accumulator with a C-clamp. 6. Install the accumulator retainer ring (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Hydraulic Brake Booster Accumulator Replacement > Page 11788 7. Release the C-clamp. 8. Remove the nut from the stud. 9. Remove the J26889. 10. Install the master cylinder to the hydraulic booster. 11. Release the park brake and unblock the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Hydraulic Brake Booster Accumulator Replacement > Page 11789 Hydraulic Brake Booster: Service and Repair Hydraulic Brake Booster Replacement Hydraulic Brake Booster Replacement Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. Refer to General Information to select the correct fluid. Checking and Adding Fluid For information on checking and adding fluid to the hydraulic booster system, refer to Checking and Adding Power Steering Fluid (With Hydroboost) Checking and Adding Power Steering Fluid (Without Hydroboost) in Power Steering System. Bleeding the Hydraulic Booster System Refer to Bleeding the Power Steering System in Power Steering System. Flushing the Hydraulic Booster System Refer to Flushing the Power Steering System in Power Steering System. Removal Procedure 1. Apply the park brake and block the wheels. 2. Disconnect the inlet hose, the steering gear, and the return hoses from the booster assembly. 3. Remove the master cylinder. 4. Remove the stop lamp switch. 5. Remove the 4 booster to bulkhead nuts. 6. Remove the booster assembly. 7. Remove the gasket. Installation Procedure 1. Install the gasket. 2. Install the booster assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Hydraulic Brake Booster Accumulator Replacement > Page 11790 3. Notice: Refer to Fastener Notice in Service Precautions. Install the 4 booster to bulkhead nuts. Tighten the nuts to 33 Nm (24 ft. lbs.). 4. Install the stop lamp switch. 5. Install the master cylinder. 6. Connect the return hose, the steering gear, and the inlet hoses. 7. Bleed the hydraulic booster system. 8. Release the park brake and unblock the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Diagrams Hydraulic Brake Booster Pump: Diagrams Supplemental Brake Assist Pump Motor With RPO JC4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Diagrams > Page 11794 Hydraulic Brake Booster Pump: Service and Repair Brake Assist Pump Motor Replacement Removal Procedure 1. Remove the vacuum hose from the brake assist pump. 2. Disconnect the electrical connector. 3. Remove the brake assist pump nuts. 4. Remove the brake assist pump from the booster by pulling the inlet tube out of the grommet. Installation Procedure 1. Install the brake assist pump to the booster by pushing the inlet tube into the grommet and aligning the studs to the holes. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake assist pump nuts. Tighten the nuts to 18 Nm (13 ft. lbs.). 3. Connect the electrical connector. 4. Install the vacuum hose to the brake assist pump. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11803 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11804 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11805 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11806 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11807 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11808 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11809 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11810 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11811 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11812 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11813 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11814 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11815 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11816 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11822 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11823 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11824 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11825 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11826 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11827 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11828 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11829 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11830 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11831 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11832 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11833 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11834 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 11835 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Engine Controls - MIL ON/DTC P0171/P0174 Diagnostics Vacuum Brake Booster: Technical Service Bulletins Engine Controls - MIL ON/DTC P0171/P0174 Diagnostics INFORMATION Bulletin No.: 08-06-04-016 Date: March 06, 2008 Subject: Diagnostic Information on MIL/SES with DTC P0171 (Fuel Trim System Lean Bank 1) and/or P0174 (Fuel Trim System Lean Bank 2) After Brake Master Cylinder Replacement Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2007 Chevrolet Silverado Classic 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2007 GMC Sierra Classic 2007-2008 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Vacuum Power Brakes (RPOs JD9, JF3, JF7) The purpose of this bulletin is to inform dealer technicians to inspect the brake master cylinder seal anytime the brake master cylinder is removed from the vacuum brake booster. A vehicle may encounter an MIL/SES light set with DTC P0171 (Fuel Trim System Lean Bank 1) and/or P0174 (Fuel Trim System Lean Bank 2) if the seal (1) is damaged or missing. To aid in diagnosis a technician may monitor the Long Term Fuel Trims with a scan tool. If a lean condition exists block off the vacuum supply line or hose to the brake booster. If the fuel trims return to normal the seal may be damaged or missing. Prior to removing the brake master cylinder the brake pedal should be applied several times with the engine OFF until the vacuum is depleted from the brake booster. It is possible that the seal could be sucked into the brake booster if the reserve vacuum is not depleted first. Remove the master cylinder and inspect the seal. Refer to Master Cylinder Replacement (JD9, JF3, JF7) in SI. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 11840 Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Remove the brake master cylinder. 3. Remove the vacuum hose from the brake booster check valve. 4. Remove the pushrod retaining clip (4) from the brake pedal stud (1). 5. Remove the stop lamp switch (2) and the pushrod (3) from the brake pedal stud (1). 6. Remove the 4 vacuum booster mounting nuts. 7. Remove the vacuum booster. 8. Remove the gasket from the booster and discard. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 11841 1. Install the gasket to the booster. 2. Install the vacuum booster. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the 4 vacuum booster mounting nuts. Tighten the nuts to 33 Nm (24 ft. lbs.). 4. Install the pushrod (3) and the stop lamp switch (2) to the brake pedal stud (1). 5. Install the pushrod retaining clip (4) to the brake pedal stud (1). 6. Install the vacuum hose to the brake booster check valve. 7. Install the master cylinder. 8. Release the park brake and unblock the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement Removal Procedure 1. Remove the vacuum brake booster check valve from the vacuum brake booster. 2. Remove the vacuum brake booster hose clamp at the check valve. 3. Remove the vacuum brake booster check valve from the hose. 4. Remove the manifold sight shield (4.8L, 5.3L, 6.0L). 5. Disconnect the vacuum brake booster hose at the engine (4.8L, 5.3L, 6.0L). 6. Disconnect the vacuum brake booster hose at the engine (4.3L). 7. Remove the vacuum brake booster hose from the vehicle. Installation Procedure 1. Connect the vacuum brake booster hose at the engine (4.8L, 5.3L, 6.0L). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair > Page 11845 2. Connect the vacuum brake booster hose at the engine (4.3L). 3. Install the manifold sight shield (4.8L, 5.3L, 6.0L). 4. Install the vacuum brake booster check valve to the hose. 5. Install the vacuum brake booster hose clamp to the check valve. 6. Install the vacuum brake booster check valve to the vacuum brake booster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 11855 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 11861 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 11867 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 11873 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11874 Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11875 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (ECBM) C1 Electronic Brake Control Module (ECBM) C2 (8600 GVW or Less w/Rear Disc Brakes Electronic Brake Control Module (ECBM) C2 (Over 8600 GVW or Rear Drum Brakes Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11876 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11877 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 4. Disconnect the chassis electrical connectors from the EBCM. 5. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11878 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 7. Disconnect the BPMV electrical connector from the EBCM. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11879 1. Connect the BPMV electrical connector to the EBCM. 2. Install the EBCM to the BPMV. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the new screws (1) in the EBCM (2). Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11880 4. connect the chassis electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Brake Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 11885 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Using needle nose pliers, compress the locking tabs at the opposite side of the master cylinder. 3. Remove the fluid level sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 11886 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Brake Pressure Differential Switch With RPO JC4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams Brake Pedal Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Park Brake Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams Traction Control Switch: Diagrams Traction Control Switch (NW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 11899 Traction Control Switch: Service and Repair Traction Control Switch Replacement (Stabilitrak) Removal Procedure 1. Remove the Instrument Panel (I/P) bezel. 2. Gently lift the retaining tabs (2) and remove the stabilitrak switch (3) from the I/P assembly (1). 3. Disconnect the harness connector from the stabilitrak switch. Installation Procedure 1. Connect the harness connector to the stabilitrak switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 11900 2. Install the stabilitrak switch (3) into the I/P assembly (1) 3. Ensure that the switch is secure into both retaining tabs (2). 4. Install the I/P bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 11909 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 11915 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11916 Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11917 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) LF Wheel Speed Sensor (WSS) RF Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11918 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Front (4 Wheel Drive) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2) shown on the 1500 Series. 4. Remove the Wheel Speed Sensor (WSS) cable mounting clip from the knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Remove the WSS cable electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11919 8. Remove the WSS mounting bolt. 9. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the WSS (5) from the hub/bearing assembly (4) shown on the 2500/3500 series. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to sensor installation. 4. Install the WSS (5) into the hub/bearing assembly (4) shown on the 2500/3500 series. Ensure that the sensor is seated flat against the hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11920 5. Notice: Refer to Fastener Notice in Service Precautions. Install the WSS mounting bolt. Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. 9. Connect the WSS cable electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 11921 10. Install the brake rotor (2) shown on the 1500 Series. 11. Install the tire and wheel. 12. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Start Switch Clutch Start Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 11928 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 11929 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 11930 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations STARTER RELAY Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 11935 Fuse Block - Underhood Label Fuse Block - Underhood Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 11936 The Starter Relay is located on the Fuse Block - Underhood. The Fuse Block - Underhood is located on the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help . Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 11941 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12-volt positive, negative ground electrical system. Do not try to jump start a vehicle, if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 1. Place the automatic transmission in PARK. 2. Block the wheels. 3. Set the parking brake. 4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 5. Turn OFF the ignition switch. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. Consult the vehicle's owner's manual for proper connections. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery.If the engine does not crank or cranks too slowly, perform the following steps: 0. Turn the ignition OFF. 1. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 2. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) Negative: Service and Repair Disconnect/Connect Procedure (Single Battery) BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY) REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Record the customer's pre-set radio stations. 2. Turn off all the lamps and accessories. 3. Turn the ignition OFF. 4. Loosen the negative battery cable bolt. 5. Remove the negative battery cable. INSTALLATION PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and battery cable end. 1. Install the negative battery cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the negative battery cable bolt. Tighten the bolt to 17 N.m (13 lb ft). 3. Re-set the customer's radio stations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 11947 Negative: Service and Repair Disconnect/Connect Procedure (Auxiliary Battery) BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (AUXILIARY BATTERY) REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Loosen the negative battery cable bolt. 4. Remove the negative battery cable. INSTALLATION PROCEDURE Caution: Refer to Battery Disconnect Caution in Service Precautions. IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and battery cable end. 1. Install the negative battery cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the negative battery cable bolt. Tighten the bolt to 17 N.m (13 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 11948 Negative: Service and Repair Replacement procedure BATTERY NEGATIVE CABLE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If necessary, remove the left front wheel house panel. 3. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the battery cable bracket bolt and bracket from the power steering pump. 4. If equipped, disconnect the accessory power fuse block front wiring harness electrical connector from the negative cable connector. 5. If equipped with a 4.8L, 5.3L, or 6.0L engine, perform the following: 1. Remove the negative cable clip from the positive cable clip. 2. Remove the engine wiring harness ground/negative cable bolt. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. If equipped with a 8.1L engine, perform the following: 1. Remove the negative cable clip from the positive cable clip. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the engine wiring harness ground/negative cable bolt. 4. Reposition the wiring harness ground and negative cables. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 11949 7. Remove the forward lamp wiring harness ground/negative cable bolt. 8. Lower the vehicle. 9. Remove the negative battery cable. INSTALLATION PROCEDURE 1. Install the negative battery cable. 2. Raise the vehicle. 3. Position the negative cable and forward lamp wiring harness ring terminals to the frame.Insert the anti-rotation tab on the forward lamp wiring harness into the hole in the frame. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the forward lamp wiring harness ground/negative cable bolt. Tighten the bolt to 9 N.m (80 lb in). 5. If equipped with a 8.1L engine, perform the following: 1. Position the wiring harness ground and negative cables. Position the anti-rotation tab on the negative cable in the correct location. 2. Install the engine wiring harness ground/negative cable bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Lower the vehicle. 4. Install the negative cable clip to the positive cable clip. IMPORTANT: The engine wiring harness ground is to be installed under the negative cable ground. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 11950 6. If equipped with a 4.8L, 5.3L, or 6.0L engine, perform the following: 1. Position the negative cable and engine wiring harness ring terminals to the engine block. Position the anti-rotation tab on the negative cable in the correct location. 2. Install the engine wiring harness ground/negative cable bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Lower the vehicle. 4. Install the negative cable clip to the positive cable clip. 7. If equipped, connect the accessory power fuse block front wiring harness electrical connector to the negative cable connector. 8. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the battery cable bracket and bolt to the power steering pump. Tighten the bolt to 25 N.m (18 lb ft). 9. If necessary, install the left front wheel house panel. 10. Connect the negative battery cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Technician Safety Information Positive: Technician Safety Information CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help . Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Technician Safety Information > Page 11955 Positive: Vehicle Damage Warnings BATTERY DISCONNECT CAUTION CAUTION: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary Positive: Service and Repair Replacement Procedure - Battery to Battery Relay - Auxiliary BATTERY POSITIVE CABLE REPLACEMENT - BATTERY TO BATTERY RELAY - AUXILIARY REMOVAL PROCEDURE 1. Remove the auxiliary battery. 2. Unclip the mega fuse from the auxiliary battery tray. 3. Remove the auxiliary positive cable to relay nut (2). 4. Remove the auxiliary battery positive cable. INSTALLATION PROCEDURE 1. Install the auxiliary battery positive cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the auxiliary positive cable to relay nut (2). Tighten the nut to 9 N.m (80 lb in). 3. Clip the mega fuse to the auxiliary battery tray. 4. Install the auxiliary battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 11958 Positive: Service and Repair Replacement procedure BATTERY POSITIVE CABLE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Unsnap the positive battery cable cap. 3. Loosen the positive battery cable. 4. Remove the positive battery cable. 5. Loosen the positive cable bolt at the underhood bussed electrical center (UBEC). IMPORTANT: The bolt is integral to the battery cable and is not removable. 6. If necessary, remove the engine sight shield. 7. Unsnap the junction block cover. 8. Remove the positive battery cable (1) from the junction block. 9. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the negative cable clip from the positive cable clip. 10. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 11959 11. If equipped with a 8.1L engine, remove the negative cable clip from the positive cable clip. 12. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 13. Remove the positive battery cable channel bolt. 14. Slide the channel pin out of the oil pan tab. 15. Remove the positive battery cable from the channel. 16. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the battery cable bracket bolt and bracket from the power steering pump. 17. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the starter lead nut. 18. Remove the positive cable from the starter. 19. Remove the positive cable clip from the clip on the oil pan. 20. Remove the positive cable from the clip on the oil pan. 21. Remove the positive battery cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 11960 22. If equipped with a 8.1L engine, remove the starter lead nut. 23. Remove the positive cable from the starter. 24. Remove the positive cable clip nut. 25. Remove the positive cable from the engine harness clip. 26. Remove the positive battery cable. INSTALLATION PROCEDURE 1. If equipped with a 8.1L engine, install the positive battery cable. 2. install the positive cable to the engine harness clip. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the positive cable clip nut. Tighten the nut to 8 N.m (71 lb in). 4. Install the positive cable to the starter. 5. Install the starter lead nut. Tighten the starter lead nut to 9 N.m (80 lb in). 6. If equipped with a 4.8L, 5.3L, or 6.0L engine, Install the positive battery cable. 7. Install the positive cable to the clip on the oil pan. 8. Install the positive cable clip to the clip on the oil pan. 9. Install the positive cable to the starter. 10. Install the starter lead nut. Tighten the nut to 9 N.m (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 11961 11. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the battery cable bracket and bolt. Tighten the bolt to 25 N.m (18 lb ft). 12. Install the positive battery cable to the channel. 13. Slide the channel pin into the oil pan tab. 14. Install the positive battery cable channel bolt. Tighten the bolt to 12 N.m (106 lb in). 15. Lower the vehicle. 16. If equipped with a 8.1L engine, install the negative cable clip to the positive cable clip. 17. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the negative cable clip to the positive cable clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 11962 18. Install the positive cable (1) into the junction block. 19. Snap the junction block cover closed. 20. If necessary, install the engine sight shield. 21. Tighten the positive cable bolt at the UBEC. Tighten the bolt to 9 N.m (80 lb in). 22. Install the positive battery cable. 23. Tighten the positive battery cable. Tighten the bolt to 17 N.m (13 lb ft). 24. Snap the positive battery cable cap closed. 25. Connect the negative battery cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 11963 Positive: Service and Repair Replacement Procedure - Battery Relay to Starter - Auxiliary BATTERY POSITIVE CABLE REPLACEMENT - BATTERY RELAY TO STARTER - AUXILIARY REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the auxiliary battery negative cable. 2. Reposition the boot. 3. Remove the auxiliary positive battery cable nut. 4. Remove the auxiliary positive battery cable from the auxiliary relay. 5. Remove the auxiliary positive battery cable clip from the battery tray. 6. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 7. Remove the auxiliary cable clip bolt from the frame. 8. Remove the starter lead nut. 9. Remove the auxiliary positive battery cable from the starter stud. 10. Remove the auxiliary positive battery cable. INSTALLATION PROCEDURE 1. Install the auxiliary positive battery cable. 2. Install the auxiliary positive battery cable to the starter stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 11964 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the starter lead nut. Tighten the nut to 9 N.m (80 lb in). 4. Install the auxiliary cable clip bolt to the frame. Tighten the bolt to 10 N.m (89 lb in). 5. Lower the vehicle. 6. Install the auxiliary positive battery cable clip to the battery tray. 7. Install the auxiliary positive battery cable to the auxiliary relay. 8. Install the auxiliary positive battery cable nut. Tighten the nut to 8 N.m (71 lb in). 9. Position the boot. 10. Connect the auxiliary battery negative cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 11969 Left Front Corner Of Engine Compartment Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11972 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11973 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11974 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11975 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11976 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11977 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11978 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11979 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11980 Alternator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11981 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11982 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11983 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11984 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11985 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11986 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11987 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11988 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11989 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11990 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11991 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11992 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11993 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11994 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11995 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11996 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11997 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11998 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 11999 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12000 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12001 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12002 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12003 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12004 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12005 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12006 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12007 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12008 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12009 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12010 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12011 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12012 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12013 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12014 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12015 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12016 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12017 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12018 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12019 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12020 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12021 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12022 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12023 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12024 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12025 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12026 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12027 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12028 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12029 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12030 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12031 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12032 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12033 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12034 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12035 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12036 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12037 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12038 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12039 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12040 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12041 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12042 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12043 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12044 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12045 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12046 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12047 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12048 Alternator: Connector Views Generator Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12049 Generator Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12050 Generator - Left (With RPO Code K65/8X5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 12051 Generator Battery Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Battery Control Module Replacement Alternator: Service and Repair Generator Battery Control Module Replacement GENERATOR BATTERY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the engine harness electrical connector from the generator battery control module. 2. Remove the negative battery cable. 3. Cut the tie straps and electrical tape attaching the generator battery control module to the battery cable. 4. Squeeze the negative battery cable branches together. 5. Slide the generator battery control module off of the negative battery cable. IMPORTANT: Note the position of the generator battery control module prior to removal. INSTALLATION PROCEDURE 1. Slide the NEW generator battery control module up onto the negative battery cable. IMPORTANT: Ensure that the tape tab is pointing away from the generator battery control module prior to installation. 2. Using NEW tie straps and electrical tape, attach the generator battery control module to the negative battery cable. 3. Install the negative battery cable. 4. Connect the engine harness electrical connector to the generator battery control module. 5. Program the generator battery control module. Refer to Generator Battery Control Module Programming and Setup. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page 12054 Alternator: Service and Repair Alternator Cable Replacement GENERATOR CABLE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If necessary, remove the engine sight shield. 3. Remove the generator cable from the generator, perform the following: 1. Reposition the boot to expose the stud. 2. Remove the generator cable nut. 3. Remove the generator cable from the stud. 4. Open the positive cable junction block. 5. Remove the generator cable nut. 6. Remove the generator cable (2) from the junction block. INSTALLATION PROCEDURE 1. Install the generator cable (2) to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the generator cable nut. Tighten the nut to 9 N.m (80 lb in). 3. Close the positive cable junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page 12055 4. Install the generator cable to the generator, perform the following: 1. Install the generator cable to the stud. 2. Install the generator cable nut. Tighten the nut to 9 N.m (80 lb in). 3. Position the boot to cover the stud. 5. If necessary, install the engine sight shield. 6. Connect the negative battery cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page 12056 Alternator: Service and Repair Generator Bracket Replacement GENERATOR BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Remove the battery cable junction block bracket bolts. 2. Remove the generator. 3. Remove the power steering pump. 4. Remove the generator bracket bolts. 5. Remove the generator bracket. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page 12057 1. Install the generator bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the generator bracket bolts. Tighten the bolts to 50 N.m (37 lb ft). 3. Install the power steering pump. 4. Install the generator. 5. Install the battery cable junction block bracket bolts. Tighten the bolts to 9 N.m (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page 12058 Alternator: Service and Repair Generator Replacement GENERATOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt. 3. If necessary, remove the engine sight shield. 4. Disconnect the generator electrical connector (3). 5. Remove the generator cable from the generator, perform the following: 1. Slide the boot down revealing the terminal stud. 2. Remove the generator cable nut from the terminal stud. 3. Remove the generator cable. 6. Remove the generator bolts. 7. Remove the generator. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page 12059 1. Install the generator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the generator bolts. Tighten the bolts to 50 N.m (37 lb ft). 3. Install the generator cable to the generator, perform the following: 1. Install the generator cable. 2. Install the generator cable nut to the terminal stud. Tighten the nut to 9 N.m (80 lb in). 3. Slide the boot over the terminal stud. 4. Connect the generator electrical connector (3). 5. If necessary, install the engine sight shield. 6. Install the accessory drive belt. 7. Connect the negative battery cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement Voltage Regulator: Customer Interest Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement > Page 12068 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement Voltage Regulator: All Technical Service Bulletins Engine Controls - Battery Lamp ON After PCM Replacement Bulletin No.: 05-08-49-010A Date: April 18, 2005 INFORMATION Subject: Information on ReSetting the Battery Light If It Remains Illuminated After PCM Replacement Models: 2005 Cadillac Escalade 2005 Chevrolet Avalanche, Silverado 1500 Series, Suburban, Tahoe 2005 GMC Denali, Sierra 1500 Series, Sierra Denali, Yukon XL with Regulated Voltage Control (RVC) Module Supercede: This bulletin is being revised to include additional information on the IPC/RVC module. Please discard Corporate Bulletin Number 05-08-49-010 (Section 08 - Body and Accessories). After successfully reprogramming a service Powertrain Control Module (PCM) with Regulated Voltage Control (RVC) module, the technician may find the battery light is illuminated even after multiple ignition cycles. The instrument panel cluster (IPC) receives a battery light request from the RVC module, not the PCM. The PCM for the above-mentioned vehicles for model year 2005 may contain old PCM software that sends a Class2 message (Alternator Lamp) to the IPC. If the IPC receives a message, the IPC learns that the PCM sent the message and expects the PCM to always send the message. If the IPC does not receive the message from the PCM, the battery light will illuminate. Once the service PCM is programmed with latest model year 2005 software, the PCM will never send this Class2 message again. ^ Remove the IPC/DIC fuse from the Underhood Fuse Block for approximately 30 seconds. Refer to the diagram for the location of the fuse. ^ Disconnect the Positive Battery terminal for approximately 30 seconds and then reconnect. If this method is used, make sure to save all preset Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-49-010A > Apr > 05 > Engine Controls - Battery Lamp ON After PCM Replacement > Page 12074 memory functions on all vehicle options/accessories. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Voltage Regulator: > 04-08-50-016C > Aug > 05 > Interior Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Voltage Regulator: > 04-08-50-016C > Aug > 05 > Interior Erratic Memory Seat Operation > Page 12080 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Voltage Regulator: > 04-08-50-016C > Aug > 05 > Interior Erratic Memory Seat Operation > Page 12086 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > Clutch Start Switch Clutch Start Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 12092 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 12093 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > Clutch Start Switch > Page 12094 Clutch Pedal Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 12099 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 12100 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 12101 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > Remote Starting System - System Inoperative Diagnostics Keyless Starting System: Technical Service Bulletins Remote Starting System - System Inoperative Diagnostics INFORMATION Bulletin No.: 08-08-52-002 Date: February 27, 2008 Subject: Diagnostic Information for Inoperative Remote Vehicle Start Models: 2005-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2008 HUMMER H2 with Remote Keyless Entry RPOs AP3 or AP8 Remote Vehicle Start (RVS) Inoperative Diagnostic Concerns Information on Hood Latch Switches One of the many components involved in the Remote Vehicle Starting System is the Hood Latch Switch. The state of this switch is checked by the BCM during a remote vehicle start request and the component must function properly in order for the vehicle to commence a remote start event. During the infancy of this option (RPO AP3/AP8) parts return analysis showed a significantly shorter than expected component life for the Hood Latch Switch shared across many different GM vehicles. The switches currently being factory installed, and sent as service replacement parts, are vastly improved in design and suitably robust. Most hood latch switches currently returned under warranty are analyzed and determined to have no trouble found (NTF). It is understandable and desirable that technicians gain familiarity with the vehicles they service on a daily basis, however it is required that technicians follow Strategy Based Diagnostics before replacing this switch. Important: The ONLY way to repair or replace a hood latch switch is to replace the LATCH ASSEMBLY. The switch CANNOT be serviced separately from the latch and is NOT AVAILABLE from GMSPO. Any effort to remove the switch from the latch will permanently damage the switch and void the warranty coverage of that part. Important: The hood switch provides status of the hood to the BCM for RVS purposes. The switch is integrated into the hood latch assembly. The hood ajar switch provides two separate inputs to the BCM. These separate inputs allow the BCM to actively monitor for a hood ajar switch fault. RVS System Operation The remote vehicle start (RVS) function allows engine starting while not in the vehicle. It also allows the vehicle HVAC system and other vehicle systems to enable providing a comfortable vehicle upon entry. RVS functions have an operating range of up to 59 m (195 ft) depending on conditions. The RVS sequence begins by pressing and releasing the lock button and then pressing and holding the RVS buttons on the keyless entry transmitter. The turn signal lamps will illuminate to indicate the vehicle has received the remote start request. Each time an RVS is performed the vehicle doors are locked; however they may then be unlocked/locked with the transmitter or vehicle key at any time. Once activated the engine is allowed to run for 10 minutes. The RVS time may be extended by an additional 10 minutes by again pressing and releasing the lock button and then pressing and holding the RVS buttons on the transmitter. This feature is called an RVS continue and allows a maximum of 20 minutes of engine running. If the RVS continue is performed at 7 minutes into the initial 10 minute time-out a total of 17 minutes of engine running would occur. The RVS event may be suspended at any time by pressing only the RVS button on the transmitter or by entering the vehicle and turning ON the hazard lamps. RVS System Description Remote vehicle start (RVS) begins as a Radio Frequency (RF) message received by the remote control door lock receiver (RCDLR) from a keyless entry transmitter. The RVS request is sent by the RCDLR to the body control module (BCM) via serial data line. The BCM monitors system conditions such as content theft deterrent (CTD) closures ajar status and body DTCs to determine if an RVS event will occur. If conditions are determined to be acceptable the RVS message is sent to the engine control module (ECM). The ECM monitors system conditions such as engine control parameters and vehicle theft deterrent (VTD) to determine if engine starting will be allowed. If conditions are acceptable the ECM will initiate engine starting. During Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > Remote Starting System - System Inoperative Diagnostics > Page 12106 the engine run time in an RVS attempt before the operator enters the vehicle the ECM may discontinue engine operation if system conditions require it or a message is received from the BCM requesting the engine be turned OFF. Reasons an RVS event will NOT Happen The RVS System WILL NOT operate if any of the following conditions are present: ^ A current vehicle DTC that illuminates the malfunction indicator lamp (MIL) is set - obtain vehicle DTCs. ^ Keyless Entry Transmitter is not Operational. ^ The vehicle is in Valet Mode. ^ RVS is Disabled through Vehicle Personalization. ^ More than 2 Remote Starts have been attempted. ^ The HAZARD switch is in the ON position. ^ A current HAZARD switch DTC is set. ^ A current HOOD AJAR DTC is set. ^ Rear compartment lid is ajar. ^ Any Door is not locked. ^ The Content Theft Deterrent (CTD) system detects an alarm trigger. ^ Engine RPM greater than 0 Detected. ^ Excessive Coolant TEMP is registered. ^ Accelerator pedal position greater than 0 percent. ^ Vehicle is not in PARK. ^ A current Vehicle Theft Deterrent Malfunction DTC. ^ A current Automatic Transmission Shift Lock Control System DTC is set. ^ A vehicle speed sensor signal is detected by the ECM. ^ Vehicle power mode is incorrect. Diagnostic Information Starting Point For additional assistance refer to Remote Vehicle Start Inoperative in the Electronic Service Information. This section will guide you through the complete Strategy Based Diagnostics and provide Specific Diagnostic Procedure Instructions. Warranty Information Please refer to the published Labor Time Guides and claim the corresponding labor operation for the component(s) replaced. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Heat Shield > Component Information > Service and Repair Starter Heat Shield: Service and Repair STARTER SHIELD REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter motor. 2. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the starter heat shield. 3. If equipped with a 8.1L engine, remove the starter heat shield bolts, and nut. 4. Remove the starter heat shield. INSTALLATION PROCEDURE 1. If equipped with a 8.1L engine, install the starter heat shield. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the starter heat shield bolts, and nut. - Tighten the bolts to 3 N.m (35 lb in). - Tighten the nut to 5 N.m (44 lb in). 3. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the starter heat shield. 4. Install the starter motor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations STARTER RELAY Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 12114 Fuse Block - Underhood Label Fuse Block - Underhood Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 12115 The Starter Relay is located on the Fuse Block - Underhood. The Fuse Block - Underhood is located on the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations Starter Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Cigar Lighter And Auxiliary Power Outlet - Front (Except RPO code UQ7 And Y91) Cigar Lighter And Auxiliary Power Outlet - Front (Except RPO Code UQ7 And Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Cigar Lighter And Auxiliary Power Outlet - Front (Except RPO code UQ7 And Y91) > Page 12124 Console Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12127 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12128 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12129 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12130 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12131 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12132 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12133 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12134 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12135 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12136 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12137 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12138 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12139 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12140 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12141 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12142 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12143 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12144 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12145 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12146 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12147 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12148 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12149 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12150 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12151 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12152 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12153 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12154 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12155 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12156 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12157 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12158 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12159 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12160 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12161 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12162 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12163 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12164 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12165 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12166 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12167 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12168 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12169 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12170 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12171 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12172 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12173 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12174 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12175 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12176 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12177 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12178 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12179 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12180 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12181 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12182 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12183 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12184 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12185 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12186 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12187 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12188 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12189 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12190 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12191 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12192 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12193 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12194 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12195 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12196 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12197 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12198 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12199 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12200 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12201 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12202 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12203 Auxiliary Power Outlet: Connector Views Auxiliary Power Outlet - Bin (With RPO Code Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12204 Auxiliary Power Outlet - Console (With RPO Code UQ7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12205 Auxiliary Power Outlet - Front (Except RPO Code Z75) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 12206 Auxiliary Power Outlet: Description and Operation POWER OUTLETS - DESCRIPTION AND OPERATION The 120-volt auxiliary power outlets (APO) are located in the cab and within the pickup bed. The APOs provide 120 volts A/C at 60 hertz with a total a total circuit current of 20 amps. All of the APOs are protected by a ground fault detector located in the starter generator control module (SGCM). The ground fault detector will turn OFF all the outlets if a short to ground is detected or a current overload of greater than 20 amps occurs. After correcting the APOs circuit fault, the APO momentary push button switch on the instrument panel (I/P) may be pressed to reset the ground fault detector. The 120-volt APOs are activated with a momentary push button that located on the I/P. There are 3 states displayed by the 120-volt APO switch indicator lamp. If the lamp is illuminated, then the APOs circuit is activated and the vehicle is in the normal mode. A flashing indicator lamp signals that the system is in the continuous mode. If the indicator is OFF, the 120-volt A/C APOs are OFF. For more information on the hybrid system, review the following Description and Operations. - Energy Storage Box (ESB) Description and Operation in Starting and Charging - Hybrid Control Module (HCM) Description and Operation in Starting and Charging - Starter/Generator Description and Operation in Starting and Charging - Starter/Generator Control Module (SGCM) Description and Operation in Starting and Charging Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Auxiliary Power Outlet: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with the Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check will provide the following information: - The identification of the control modules which command the system. - The ability of the control modules to communicate through the serial data circuit. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12209 Auxiliary Power Outlet: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Ignition 1 Signal: The scan tool displays the current voltage at the battery. GEN L-Terminal Signal Command: The scan tool displays OK/No Output. The scan tool displays OK until malfunction is detected on the generator L terminal circuit, then it reads No Output. GEN F-Terminal Signal: The scan tool displays 0-100%. The scan tool displays 0-5% until the engine is running, then the percentage value varies depending on electrical loads. Powertrain Control Module (PCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement Auxiliary Power Outlet: Service and Repair 120 Volt Receptacle Replacement 120 VOLT RECEPTACLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the receptacle outlet screws (2). 2. Remove the receptacle outlet (3) from the receptacle box (1). 3. Disconnect the receptacle electrical connections. INSTALLATION PROCEDURE 1. Connect the receptacle electrical connections. 2. Install the receptacle outlet (3) to the receptacle box (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the receptacle outlet screws (2). Tighten the screws to 2 N.m (18 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement > Page 12212 Auxiliary Power Outlet: Service and Repair Accessory Power Receptacle Replacement - 12 Volt ACCESSORY POWER RECEPTACLE REPLACEMENT - 12 VOLT TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power supply fuse. 2. Lift up the front cover of the receptacle. 3. Insert the J 42059 into the receptacle sleeve. Tilt the tool so that the tool fits into the slots on the sides of the receptacle sleeve. 4. Hold the plastic ring in place. Pull the receptacle out of the assembly in order to remove the outlet. 5. If J 42059 tool fails to release the power port/lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. 6. Remove the electrical connector from the socket. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement > Page 12213 1. Insert the plastic ring into the opening and snap the plastic ring into place. 2. Connect the electrical connector to the receptacle. 3. Insert the receptacle through the plastic ring gently by hand until the receptacle ring is sealed. 4. Install the power supply fuse. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Page 12214 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) Fuse: Locations Fuse Block - Underhood - Cooling Fan (10 Series) Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12221 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12222 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12223 Fuse Block - Underhood - Cooling Fan (10 Series) Wire Entry Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12224 Fuse: Locations Fuse Block - Underhood - Secondary Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12225 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12226 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12227 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12228 Fuse Block - Underhood - Secondary Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12229 Fuse Block - Underhood - Secondary Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12230 Fuse: Locations Fuse Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12231 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12232 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12233 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12234 Fuse: Locations Fuse Block - Underhood Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12235 Application Table Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12236 Application Table Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12237 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12238 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12239 Fuse: Locations Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12240 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12241 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12242 Fuse Block - Underhood - Cooling Fan (10 Series) Wire Entry Fuse Block - Underhood - Secondary Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12243 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12244 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12245 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12246 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12247 Fuse Block - Underhood - Secondary Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12248 Fuse Block - Underhood - Secondary Wire Entry Part 2 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12249 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12250 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12251 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12252 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12253 Application Table Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12254 Application Table Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12255 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12256 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12257 Location View Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12258 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12259 Junction Block - I/P Wire Entry Part 2 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) Fuse: Application and ID Fuse Block - Underhood - Cooling Fan (10 Series) Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12262 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12263 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12264 Fuse Block - Underhood - Cooling Fan (10 Series) Wire Entry Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12265 Fuse: Application and ID Fuse Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12266 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12267 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12268 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12269 Fuse: Application and ID Fuse Block - Underhood Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12270 Application Table Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12271 Application Table Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12272 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12273 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12274 Fuse: Application and ID Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12275 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12276 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12277 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Left I/P Body Control Module (BCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Left I/P > Page 12282 Fuse Block: Locations Fuse Block - Underhood FUSE BLOCK - UNDERHOOD Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Left I/P > Page 12283 Fuse Block - Underhood Label Fuse Block - Underhood Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Left I/P > Page 12284 The Fuse Block - Underhood is located on the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12287 Fuse Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12288 Fuse Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12289 Fuse Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12290 Fuse Block - I/P C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12291 Fuse Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12292 Fuse Block - I/P C4 (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12293 Fuse Block - Underhood Top View Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12294 Fuse Block - Underhood - Cooling Fan (10 Series) Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12295 Fuse Block - Underhood C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12296 Fuse Block - Underhood C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12297 Fuse Block - Underhood C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12298 Fuse Block - Underhood C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12299 Fuse Block - Underhood C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12300 Fuse Block - Underhood C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12301 Fuse Block - Underhood C2 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12302 Fuse Block - Underhood C2 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12303 Fuse Block - Underhood C3 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12304 Fuse Block - Underhood C3 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12305 Fuse Block - Underhood C4 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12306 Fuse Block - Underhood C4 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12307 Fuse Block - Underhood C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12308 Fuse Block - Underhood C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12309 Fuse Block - Underhood C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12310 Fuse Block - Underhood C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12311 Junction Block - I/P - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12312 Junction Block - I/P - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12313 Junction Block - I/P - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12314 Junction Block - I/P - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12315 Junction Block - I/P - C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12316 Junction Block - I/P - C8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12317 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12318 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12319 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12320 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12321 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12322 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12323 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12324 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12325 Relay Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12326 Relay Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12327 Relay Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12328 Relay Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12329 Relay Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12330 Relay Block - I/P C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12331 Relay Block - I/P C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12332 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12333 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12334 Relay Block - I/P C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12335 Relay Block - I/P C10 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label Fuse Block: Application and ID Fuse Block - I/P Label Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12338 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12339 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12340 Fuse Block: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12341 Fuse Block - Underhood Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12342 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12343 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12344 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12345 Fuse Block: Application and ID Fuse Block - Underhood - Cooling Fan Fuse Block - Underhood - Cooling Fan Fuse Block - Underhood - Cooling Fan Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12346 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12349 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12350 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12351 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12352 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12353 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12354 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Customer Interest for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Customer Interest for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 12363 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 12369 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Page 12370 Ground Strap: Service and Repair GROUND STRAP REPLACEMENT REMOVAL PROCEDURE 1. If necessary, remove the engine sight shield. 2. Remove the engine wiring harness ground bolt. 3. Reposition the engine wiring harness ground and ground strap. 4. Remove the ground strap nut from the stud at the front of dash. 5. Remove the ground strap from the stud. INSTALLATION PROCEDURE 1. Install the ground strap to the stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ground strap nut to the stud at the front of dash. Tighten the nut to 9 N.m (80 lb in). 3. Position the ground strap and engine wiring harness ground. 4. Install the engine wiring harness ground bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Page 12371 Tighten the bolt to 16 N.m (12 lb ft). 5. If necessary, install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 12380 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12386 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12387 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12388 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12389 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12390 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12391 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 12396 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12402 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12403 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12404 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12405 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12406 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12407 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12416 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12422 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 Multiple Junction Connector: Diagrams C100 - C199 C100 I/P Harness To Engine Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12425 C102 I/P Harness To Chassis Harness (Without RPO Code NYS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12426 C102 I/P Harness To Chassis Harness (With RPO Code NYS) Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12427 C102 I/P Harness To Chassis Harness (With RPO Code NYS) Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12428 C104 I/P Harness To Forward Lamp Harness (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12429 C104 I/P Harness To Forward Lamp Harness (Without RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12430 C106 Engine Harness To I/P Harness (With RPO Code PTO) C115 Engine Harness To Knock Sensor Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12431 C117 Battery Negative Harness To Accessory Jumper Harness (With RPO Code 9L4) C119 Accessory Jumper Harness To Brake/Clutch Harness (With RPO Code 9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12432 C125 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12433 C127 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12434 C148 Engine Harness To Coil Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12435 C149 Engine Harness To Coil Jumper Harness C150 4-Wheel Drive Harness To 4-Wheel Drive Jumper Harness (With RPO Code NP8/NP1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12436 C151 I/P Harness To ATC Harness (With RPO Code NP1/NP8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12437 C152 Chassis Harness To Engine Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12438 C153 4-Wheel Drive Harness To Engine Harness (With RPO Code NP1/NP2/NP8) C154 I/P Harness To ATC Harness (With RPO Code NP1/NP8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12439 C161 Roof Beacon Harness To Chassis Harness (With RPO Code 5Y0) C198 I/P Harness To Chassis Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12440 C160 Chassis Harness To Brake/Clutch Harness (With RPO Code 5X7/5Y0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12441 Multiple Junction Connector: Diagrams C200 - C299 C201 Steering Column Harness To I/P Harness Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12442 C201 Steering Column Harness To I/P Harness Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12443 C202 I/P Harness To Brake/Clutch Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12444 C210 Brake/Clutch Harness To Beacon Harness (With RPO Code 5G4/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12445 C214 I/P Harness To Headliner Harness (With RPO Code U42/UE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12446 C214 Infotainment Harness To Headliner Harness (With RPO Code UE1, Without RPO Code U42) C216 Brake/Clutch Harness To Fuse Block Jumper Harness (With RPO Code 9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12447 C220 I/P Harness To Infotainment Jumper Harness (With RPO Code UQ7, Without RPO Code Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12448 C221 I/P Harness To Body Harness (With Single Stage Air Bag) (With RPO Code HVY) C221 I/P Harness To Body Harness (With Dual Stage Air Bag) (With RPO Code AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12449 C222 I/P Harness To Body Harness C230 I/P Harness (UE1 And Y91) Or Infotainment Jumper Harness (UE1 Without RPO Code Y91) To Roofmarker Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12450 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Code ZX3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12451 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Code 5X7, 5G4, 5Y0, And TRW) C249 I/P Harness To Bezel Harness (Except Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12452 C249 Console Harness To Bezel Harness (With RPO Code Y91) C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code HVY) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12453 C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12454 C277 Steering Wheel Module Coil To Steering Wheel Harness (With RPO Code UK3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12455 Multiple Junction Connector: Diagrams C300 - C399 C305 Body Harness To Drivers Seat Harness (With RPO Code AG1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12456 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12457 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12458 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12459 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12460 C310 Body Harness To Left Rear Door Harness (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12461 C320 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12462 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12463 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12464 C322 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12465 C323 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AG1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12466 C324 Lumbar Bolster Harness To Seat Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12467 C325 Heated Seat Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12468 C326 Heated Seat Jumper Harness To Passenger Seat Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12469 C329 Lumbar Bolster Harness To Passenger Seat Harness (With RPO Code AG2) C330 Body Harness To Passenger Seat Harness (With RPO Code AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12470 C350 Engine Harness To 4-Wheel Drive Harness (With RPO Code NP1/NP2/ NP8) C355 Header Harness To Overhead Console (Without RPO Code UG1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12471 C355 Header Harness To Overhead Console (With RPO Code UG1) C353 Right A-Pillar Harness To The Sunroof Harness (With RPO Code CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12472 C388 Seat Motor Jumper Harness To Passenger Seat Harness (With RPO Code AG2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12473 C396 Body Harness To Right Rear Door Harness (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12474 C399 Body Harness To Passenger Seat Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12475 Multiple Junction Connector: Diagrams C400 - C499 C404 Left Clearance Lamp Harness To License Lamp Harness (With RPO Code NYS/R05) C405 Right Clearance Lamp Harness To License Lamp Harness (With RPO Code NYS/R05) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12476 C429 Chassis Harness To Camper/5th Wheel Jumper Harness (With RPO Code UY2) C429 Chassis Harness To Camper/5th Wheel Jumper Harness (With RPO Code UY2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12482 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12483 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12484 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12485 Relay Box: Locations Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12486 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12487 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12490 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12491 Relay Box: Diagrams Junction Block - Rear Lamps - C2 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12492 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12493 Relay Box: Diagrams Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12494 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12495 Relay Box: Diagrams Junction Block - Rear Lamps - C4 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12496 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12497 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12498 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12499 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12500 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12501 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12502 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12503 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12504 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12505 Junction Block - I/P - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12506 Junction Block - I/P - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12507 Junction Block - I/P - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12508 Junction Block - I/P - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12509 Junction Block - I/P - C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12510 Junction Block - I/P - C8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12511 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12512 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12513 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12514 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12515 Relay Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12516 Relay Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12517 Relay Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12518 Relay Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12519 Relay Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12520 Relay Block - I/P C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12521 Relay Block - I/P C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12522 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12523 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12524 Relay Block - I/P C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12525 Relay Block - I/P C10 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12528 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12529 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12530 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12531 Relay Box: Application and ID Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12532 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12533 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12536 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12537 Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12538 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12539 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12540 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12541 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12546 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12547 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12548 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12549 Relay Box: Locations Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12550 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 12551 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12554 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12555 Relay Box: Diagrams Junction Block - Rear Lamps - C2 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12556 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12557 Relay Box: Diagrams Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12558 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12559 Relay Box: Diagrams Junction Block - Rear Lamps - C4 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12560 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12561 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12562 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12563 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12564 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12565 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12566 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12567 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12568 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12569 Junction Block - I/P - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12570 Junction Block - I/P - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12571 Junction Block - I/P - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12572 Junction Block - I/P - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12573 Junction Block - I/P - C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12574 Junction Block - I/P - C8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12575 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12576 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12577 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12578 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12579 Relay Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12580 Relay Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12581 Relay Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12582 Relay Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12583 Relay Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12584 Relay Block - I/P C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12585 Relay Block - I/P C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12586 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12587 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12588 Relay Block - I/P C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 12589 Relay Block - I/P C10 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12592 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12593 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12594 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12595 Relay Box: Application and ID Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12596 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 12597 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12600 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12601 Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12602 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12603 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12604 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 12605 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12614 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12615 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12616 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12621 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: Customer Interest Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 12626 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12632 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12633 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12634 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12639 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12640 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12641 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12642 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12643 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12644 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12649 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 12654 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: All Technical Service Bulletins Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 12659 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12665 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12666 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12667 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12668 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12669 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12670 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 12675 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Cigar Lighter And Auxiliary Power Outlet - Front (Except RPO code UQ7 And Y91) Cigar Lighter And Auxiliary Power Outlet - Front (Except RPO Code UQ7 And Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Cigar Lighter And Auxiliary Power Outlet - Front (Except RPO code UQ7 And Y91) > Page 12681 Console Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12684 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12685 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12686 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12687 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12688 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12689 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12690 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12691 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12692 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12693 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12694 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12695 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12696 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12697 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12698 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12699 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12700 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12701 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12702 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12703 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12704 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12705 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12706 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12707 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12708 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12709 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12710 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12711 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12712 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12713 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12714 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12715 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12716 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12717 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12718 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12719 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12720 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12721 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12722 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12723 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12724 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12725 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12726 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12727 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12728 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12729 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12730 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12731 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12732 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12733 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12734 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12735 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12736 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12737 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12738 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12739 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12740 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12741 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12742 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12743 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12744 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12745 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12746 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12747 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12748 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12749 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12750 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12751 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12752 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12753 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12754 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12755 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12756 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12757 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12758 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12759 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12760 Auxiliary Power Outlet: Connector Views Auxiliary Power Outlet - Bin (With RPO Code Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12761 Auxiliary Power Outlet - Console (With RPO Code UQ7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12762 Auxiliary Power Outlet - Front (Except RPO Code Z75) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 12763 Auxiliary Power Outlet: Description and Operation POWER OUTLETS - DESCRIPTION AND OPERATION The 120-volt auxiliary power outlets (APO) are located in the cab and within the pickup bed. The APOs provide 120 volts A/C at 60 hertz with a total a total circuit current of 20 amps. All of the APOs are protected by a ground fault detector located in the starter generator control module (SGCM). The ground fault detector will turn OFF all the outlets if a short to ground is detected or a current overload of greater than 20 amps occurs. After correcting the APOs circuit fault, the APO momentary push button switch on the instrument panel (I/P) may be pressed to reset the ground fault detector. The 120-volt APOs are activated with a momentary push button that located on the I/P. There are 3 states displayed by the 120-volt APO switch indicator lamp. If the lamp is illuminated, then the APOs circuit is activated and the vehicle is in the normal mode. A flashing indicator lamp signals that the system is in the continuous mode. If the indicator is OFF, the 120-volt A/C APOs are OFF. For more information on the hybrid system, review the following Description and Operations. - Energy Storage Box (ESB) Description and Operation in Starting and Charging - Hybrid Control Module (HCM) Description and Operation in Starting and Charging - Starter/Generator Description and Operation in Starting and Charging - Starter/Generator Control Module (SGCM) Description and Operation in Starting and Charging Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Auxiliary Power Outlet: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with the Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check will provide the following information: - The identification of the control modules which command the system. - The ability of the control modules to communicate through the serial data circuit. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12766 Auxiliary Power Outlet: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Ignition 1 Signal: The scan tool displays the current voltage at the battery. GEN L-Terminal Signal Command: The scan tool displays OK/No Output. The scan tool displays OK until malfunction is detected on the generator L terminal circuit, then it reads No Output. GEN F-Terminal Signal: The scan tool displays 0-100%. The scan tool displays 0-5% until the engine is running, then the percentage value varies depending on electrical loads. Powertrain Control Module (PCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement Auxiliary Power Outlet: Service and Repair 120 Volt Receptacle Replacement 120 VOLT RECEPTACLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the receptacle outlet screws (2). 2. Remove the receptacle outlet (3) from the receptacle box (1). 3. Disconnect the receptacle electrical connections. INSTALLATION PROCEDURE 1. Connect the receptacle electrical connections. 2. Install the receptacle outlet (3) to the receptacle box (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the receptacle outlet screws (2). Tighten the screws to 2 N.m (18 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement > Page 12769 Auxiliary Power Outlet: Service and Repair Accessory Power Receptacle Replacement - 12 Volt ACCESSORY POWER RECEPTACLE REPLACEMENT - 12 VOLT TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power supply fuse. 2. Lift up the front cover of the receptacle. 3. Insert the J 42059 into the receptacle sleeve. Tilt the tool so that the tool fits into the slots on the sides of the receptacle sleeve. 4. Hold the plastic ring in place. Pull the receptacle out of the assembly in order to remove the outlet. 5. If J 42059 tool fails to release the power port/lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. 6. Remove the electrical connector from the socket. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement > Page 12770 1. Insert the plastic ring into the opening and snap the plastic ring into place. 2. Connect the electrical connector to the receptacle. 3. Insert the receptacle through the plastic ring gently by hand until the receptacle ring is sealed. 4. Install the power supply fuse. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Page 12771 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) Fuse: Locations Fuse Block - Underhood - Cooling Fan (10 Series) Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12778 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12779 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12780 Fuse Block - Underhood - Cooling Fan (10 Series) Wire Entry Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12781 Fuse: Locations Fuse Block - Underhood - Secondary Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12782 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12783 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12784 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12785 Fuse Block - Underhood - Secondary Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12786 Fuse Block - Underhood - Secondary Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12787 Fuse: Locations Fuse Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12788 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12789 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12790 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12791 Fuse: Locations Fuse Block - Underhood Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12792 Application Table Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12793 Application Table Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12794 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12795 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12796 Fuse: Locations Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12797 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12798 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12799 Fuse Block - Underhood - Cooling Fan (10 Series) Wire Entry Fuse Block - Underhood - Secondary Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12800 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12801 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12802 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12803 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12804 Fuse Block - Underhood - Secondary Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12805 Fuse Block - Underhood - Secondary Wire Entry Part 2 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12806 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12807 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12808 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12809 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12810 Application Table Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12811 Application Table Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12812 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12813 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12814 Location View Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12815 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12816 Junction Block - I/P Wire Entry Part 2 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) Fuse: Application and ID Fuse Block - Underhood - Cooling Fan (10 Series) Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12819 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12820 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12821 Fuse Block - Underhood - Cooling Fan (10 Series) Wire Entry Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12822 Fuse: Application and ID Fuse Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12823 Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12824 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12825 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12826 Fuse: Application and ID Fuse Block - Underhood Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12827 Application Table Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12828 Application Table Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12829 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12830 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12831 Fuse: Application and ID Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12832 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12833 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Cooling Fan (10 Series) > Page 12834 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Left I/P Body Control Module (BCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Left I/P > Page 12839 Fuse Block: Locations Fuse Block - Underhood FUSE BLOCK - UNDERHOOD Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Left I/P > Page 12840 Fuse Block - Underhood Label Fuse Block - Underhood Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Left I/P > Page 12841 The Fuse Block - Underhood is located on the left side of the engine compartment to the rear of the battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12844 Fuse Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12845 Fuse Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12846 Fuse Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12847 Fuse Block - I/P C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12848 Fuse Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12849 Fuse Block - I/P C4 (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12850 Fuse Block - Underhood Top View Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12851 Fuse Block - Underhood - Cooling Fan (10 Series) Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12852 Fuse Block - Underhood C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12853 Fuse Block - Underhood C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12854 Fuse Block - Underhood C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12855 Fuse Block - Underhood C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12856 Fuse Block - Underhood C2 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12857 Fuse Block - Underhood C2 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12858 Fuse Block - Underhood C2 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12859 Fuse Block - Underhood C2 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12860 Fuse Block - Underhood C3 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12861 Fuse Block - Underhood C3 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12862 Fuse Block - Underhood C4 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12863 Fuse Block - Underhood C4 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12864 Fuse Block - Underhood C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12865 Fuse Block - Underhood C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12866 Fuse Block - Underhood C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12867 Fuse Block - Underhood C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12868 Junction Block - I/P - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12869 Junction Block - I/P - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12870 Junction Block - I/P - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12871 Junction Block - I/P - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12872 Junction Block - I/P - C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12873 Junction Block - I/P - C8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12874 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12875 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12876 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12877 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12878 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12879 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12880 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12881 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12882 Relay Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12883 Relay Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12884 Relay Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12885 Relay Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12886 Relay Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12887 Relay Block - I/P C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12888 Relay Block - I/P C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12889 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12890 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12891 Relay Block - I/P C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 12892 Relay Block - I/P C10 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label Fuse Block: Application and ID Fuse Block - I/P Label Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12895 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12896 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12897 Fuse Block: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12898 Fuse Block - Underhood Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12899 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12900 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12901 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12902 Fuse Block: Application and ID Fuse Block - Underhood - Cooling Fan Fuse Block - Underhood - Cooling Fan Fuse Block - Underhood - Cooling Fan Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Label > Page 12903 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12906 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12907 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12908 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12909 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12910 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 12911 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Customer Interest for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Customer Interest for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 12920 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 12926 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Page 12927 Ground Strap: Service and Repair GROUND STRAP REPLACEMENT REMOVAL PROCEDURE 1. If necessary, remove the engine sight shield. 2. Remove the engine wiring harness ground bolt. 3. Reposition the engine wiring harness ground and ground strap. 4. Remove the ground strap nut from the stud at the front of dash. 5. Remove the ground strap from the stud. INSTALLATION PROCEDURE 1. Install the ground strap to the stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ground strap nut to the stud at the front of dash. Tighten the nut to 9 N.m (80 lb in). 3. Position the ground strap and engine wiring harness ground. 4. Install the engine wiring harness ground bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Page 12928 Tighten the bolt to 16 N.m (12 lb ft). 5. If necessary, install the engine sight shield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 12937 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 12943 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 12944 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 12945 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 12946 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 12947 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 12948 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 12953 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12959 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12960 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12961 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12962 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12963 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12964 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 12973 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12979 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 Multiple Junction Connector: Diagrams C100 - C199 C100 I/P Harness To Engine Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12982 C102 I/P Harness To Chassis Harness (Without RPO Code NYS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12983 C102 I/P Harness To Chassis Harness (With RPO Code NYS) Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12984 C102 I/P Harness To Chassis Harness (With RPO Code NYS) Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12985 C104 I/P Harness To Forward Lamp Harness (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12986 C104 I/P Harness To Forward Lamp Harness (Without RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12987 C106 Engine Harness To I/P Harness (With RPO Code PTO) C115 Engine Harness To Knock Sensor Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12988 C117 Battery Negative Harness To Accessory Jumper Harness (With RPO Code 9L4) C119 Accessory Jumper Harness To Brake/Clutch Harness (With RPO Code 9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12989 C125 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12990 C127 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12991 C148 Engine Harness To Coil Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12992 C149 Engine Harness To Coil Jumper Harness C150 4-Wheel Drive Harness To 4-Wheel Drive Jumper Harness (With RPO Code NP8/NP1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12993 C151 I/P Harness To ATC Harness (With RPO Code NP1/NP8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12994 C152 Chassis Harness To Engine Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12995 C153 4-Wheel Drive Harness To Engine Harness (With RPO Code NP1/NP2/NP8) C154 I/P Harness To ATC Harness (With RPO Code NP1/NP8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12996 C161 Roof Beacon Harness To Chassis Harness (With RPO Code 5Y0) C198 I/P Harness To Chassis Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12997 C160 Chassis Harness To Brake/Clutch Harness (With RPO Code 5X7/5Y0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12998 Multiple Junction Connector: Diagrams C200 - C299 C201 Steering Column Harness To I/P Harness Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 12999 C201 Steering Column Harness To I/P Harness Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13000 C202 I/P Harness To Brake/Clutch Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13001 C210 Brake/Clutch Harness To Beacon Harness (With RPO Code 5G4/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13002 C214 I/P Harness To Headliner Harness (With RPO Code U42/UE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13003 C214 Infotainment Harness To Headliner Harness (With RPO Code UE1, Without RPO Code U42) C216 Brake/Clutch Harness To Fuse Block Jumper Harness (With RPO Code 9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13004 C220 I/P Harness To Infotainment Jumper Harness (With RPO Code UQ7, Without RPO Code Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13005 C221 I/P Harness To Body Harness (With Single Stage Air Bag) (With RPO Code HVY) C221 I/P Harness To Body Harness (With Dual Stage Air Bag) (With RPO Code AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13006 C222 I/P Harness To Body Harness C230 I/P Harness (UE1 And Y91) Or Infotainment Jumper Harness (UE1 Without RPO Code Y91) To Roofmarker Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13007 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Code ZX3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13008 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Code 5X7, 5G4, 5Y0, And TRW) C249 I/P Harness To Bezel Harness (Except Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13009 C249 Console Harness To Bezel Harness (With RPO Code Y91) C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code HVY) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13010 C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13011 C277 Steering Wheel Module Coil To Steering Wheel Harness (With RPO Code UK3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13012 Multiple Junction Connector: Diagrams C300 - C399 C305 Body Harness To Drivers Seat Harness (With RPO Code AG1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13013 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13014 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13015 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13016 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13017 C310 Body Harness To Left Rear Door Harness (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13018 C320 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13019 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13020 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13021 C322 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13022 C323 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AG1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13023 C324 Lumbar Bolster Harness To Seat Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13024 C325 Heated Seat Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13025 C326 Heated Seat Jumper Harness To Passenger Seat Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13026 C329 Lumbar Bolster Harness To Passenger Seat Harness (With RPO Code AG2) C330 Body Harness To Passenger Seat Harness (With RPO Code AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13027 C350 Engine Harness To 4-Wheel Drive Harness (With RPO Code NP1/NP2/ NP8) C355 Header Harness To Overhead Console (Without RPO Code UG1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13028 C355 Header Harness To Overhead Console (With RPO Code UG1) C353 Right A-Pillar Harness To The Sunroof Harness (With RPO Code CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13029 C388 Seat Motor Jumper Harness To Passenger Seat Harness (With RPO Code AG2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13030 C396 Body Harness To Right Rear Door Harness (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13031 C399 Body Harness To Passenger Seat Harness (With RPO Code AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13032 Multiple Junction Connector: Diagrams C400 - C499 C404 Left Clearance Lamp Harness To License Lamp Harness (With RPO Code NYS/R05) C405 Right Clearance Lamp Harness To License Lamp Harness (With RPO Code NYS/R05) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 13033 C429 Chassis Harness To Camper/5th Wheel Jumper Harness (With RPO Code UY2) C429 Chassis Harness To Camper/5th Wheel Jumper Harness (With RPO Code UY2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13039 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13040 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13041 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13042 Relay Box: Locations Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13043 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13044 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13047 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13048 Relay Box: Diagrams Junction Block - Rear Lamps - C2 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13049 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13050 Relay Box: Diagrams Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13051 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13052 Relay Box: Diagrams Junction Block - Rear Lamps - C4 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13053 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13054 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13055 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13056 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13057 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13058 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13059 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13060 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13061 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13062 Junction Block - I/P - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13063 Junction Block - I/P - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13064 Junction Block - I/P - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13065 Junction Block - I/P - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13066 Junction Block - I/P - C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13067 Junction Block - I/P - C8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13068 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13069 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13070 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13071 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13072 Relay Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13073 Relay Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13074 Relay Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13075 Relay Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13076 Relay Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13077 Relay Block - I/P C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13078 Relay Block - I/P C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13079 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13080 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13081 Relay Block - I/P C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13082 Relay Block - I/P C10 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13085 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13086 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13087 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13088 Relay Box: Application and ID Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13089 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13090 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13093 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13094 Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13095 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13096 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13097 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13098 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13103 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13104 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13105 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13106 Relay Box: Locations Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13107 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 13108 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13111 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13112 Relay Box: Diagrams Junction Block - Rear Lamps - C2 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13113 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13114 Relay Box: Diagrams Junction Block - Rear Lamps - C3 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13115 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13116 Relay Box: Diagrams Junction Block - Rear Lamps - C4 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13117 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13118 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13119 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13120 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13121 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13122 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13123 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13124 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13125 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13126 Junction Block - I/P - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13127 Junction Block - I/P - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13128 Junction Block - I/P - C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13129 Junction Block - I/P - C6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13130 Junction Block - I/P - C7 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13131 Junction Block - I/P - C8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13132 Junction Block - Rear Lamps - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13133 Junction Block - Rear Lamps - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13134 Junction Block - Rear Lamps - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13135 Junction Block - Rear Lamps - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13136 Relay Block - I/P C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13137 Relay Block - I/P C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13138 Relay Block - I/P C1 Part 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13139 Relay Block - I/P C1 Part 4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13140 Relay Block - I/P C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13141 Relay Block - I/P C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13142 Relay Block - I/P C5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13143 Relay Block - I/P C7 (With RPO Code Z82) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13144 Relay Block - I/P C8 (With RPO Code 5G4/5X7/5Y0/TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13145 Relay Block - I/P C9 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block - Rear Lamps - C1 > Page 13146 Relay Block - I/P C10 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13149 Location View Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13150 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13151 Junction Block - Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13152 Relay Box: Application and ID Relay Block - I/P Location View Application Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13153 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 13154 Location View Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. 3. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. 8. Install the left side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13157 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. 2. Install the retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. 4. Connect the wiring connectors to the fuse block. 5. Install the right side end panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13158 Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13159 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE 1. Install the engine electrical center bracket assembly to the front fender. 2. Install the 4 retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13160 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13161 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. 2. Install the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Left > Page 13162 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13171 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13172 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13173 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 13178 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: Customer Interest Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 13183 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13189 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13190 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13191 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13196 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13197 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13198 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13199 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13200 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13201 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 13206 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 13211 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: All Technical Service Bulletins Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 13216 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13222 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13223 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13224 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13225 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13226 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 13227 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 13232 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13238 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13239 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13240 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13241 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13242 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13243 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13244 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13245 Alignment: Technical Service Bulletins Steering/Suspension - Revised Alignment Specifications Bulletin No.: 05-03-07-006 Date: May 31, 2005 SERVICE MANUAL UPDATE Subject: Revised Wheel Alignment Specifications Models: 2005 Chevrolet Silverado 2005 GMC Sierra This bulletin is being issued to revise the Wheel Alignment Specifications in the Wheel Alignment sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13246 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13247 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13248 The information shown has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 13249 Alignment: Technical Service Bulletins Steering/Suspension - Revised Caster/Camber Adjustment Info - Revised Front Caster and Camber Adjustment Procedure # 02-03-07-002A - (Mar 24, 2005) Models: 1999-2000 Cadillac Escalade 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Express, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999 GMC Suburban 1999-2005 GMC Savana, Sierra, Yukon, Yukon XL, Yukon XL Denali This bulletin is being revised to add model years and clarify the information. Please discard Corporate Bulletin Number 02-03-07-002 (Section 03 - Suspension). When performing a wheel alignment on any of the above vehicles, please refer to the Front Caster and Camber Adjustment Procedure in SI before contacting the GM Technical Assistance Center (TAC) with issues concerning adjustments, caster out-of-spec, etc. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 13252 Alignment: Specifications Wheel Alignment Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 13253 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 13254 Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 13255 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 13256 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Definition: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Wheel alignment ^ Unbalanced steering gear The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 13257 Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure Alignment: Service and Repair Trim Height Inspection Procedure Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Make sure the vehicle is on a level surface, such as a alignment rack. 2. Remove the alignment rack floating pins. 3. Set the tire pressures to the pressure shown on the certification label. 4. Check the fuel level. Add additional weight if necessary to simulate a full tank. 5. Make sure the rear compartment is empty except for the spare tire. 6. Close the doors and hood. Z Height Measurement Important: K models only the Z height must be adjusted before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use a adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Important: All dimensions are measured vertical to the ground. Cross vehicle Z heights should be within 12 mm (0.47 inch) to be considered correct. Place hand on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (2) down to the lower corner (5) of the steering knuckle (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and the lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the highest and the lowest measurements. Refer to Trim Height Specifications. Z Height Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 13260 1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1) into the nut increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement Important: There are no specified trim heights specifications on leaf spring vehicles because it is not an adjustable feature. The height of the suspension will depend on the option content of the vehicle as well as the aftermarket equipment that is placed on the vehicle. The measurements are used for comparison only and should be within 15 mm with the vehicle at curb and no accessories. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Allow the vehicle to settle into position. 3. Important: Measure the metal to metal contact points of the rear axle to the frame on the inboard side of the leaf springs. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true D height dimension number is the average of the highest and the lowest measurements. 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension Refer to Front Coil Springs Replacement or Torsion Bar Replacement in Front Suspension. ^ Sagging rear leaf/coil springs Refer to Leaf Spring Replacement in Rear Suspension. ^ Worn rear suspension components, such as leaf spring bushings Refer to Spring Bushing Replacement in Rear Suspension. ^ Improper tire inflation Refer to Tire Inflation Pressure Specifications. ^ Improper weight distribution ^ Collision damage Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 13261 Alignment: Service and Repair Measuring Wheel Alignment (W/Rear Wheel Steering) Measuring Wheel Alignment (w/Rear Wheel Steering) Learn Wheel Alignment After replacement of the handwheel position sensor, rear wheel position sensor, or rear wheel steering control module it is necessary to perform the learn wheel alignment procedure. Alignment Procedure Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications then perform the learn alignment procedure. Learn Wheel Alignment Procedure 1. Turn ignition to ON position, with the engine ON. 2. Install the scan tool. 3. Center the steering wheel. 4. Lift the rear of the vehicle off the ground ensuring the rear wheels are centered. 5. Go to the Learn Alignment menu choice in the scan tool. Follow the prompts on the scan tool. Important: When prompted by the scan tool you must turn the steering wheel a full 90 degrees to the left and a full 90 degrees to the right and then to center and hold. If this step is not done properly then it is possible to cause a false DTC for the steering wheel position sensor. 6. Press the continue button. 7. Use the scan tool to clear all rear wheel steering DTCs. (W/O Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 13262 Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 13263 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment 1. Important: Caster measurements or valves must be compensated for the measured frame angle. Caster is relative to frame, the caster values must be compensated for the measured frame angle by using a digital protractor or equivalent on a flat portion of the frame in front of the rear tire. 2. Frame angle is positive when higher in the rear. Measure both sides of the frame and take an average from those measurements. Then add the average frame angle to the caster reading when making adjustments. 3. Frame angle is negative when lower in the rear. Measure both sides of the frame and take an average from the measurements. Then subtract the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 13264 average frame angle from the caster reading when making adjustments. 4. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. For an accurate reading, do not push or pull on the tires during the alignment process. 5. Determine the caster angle (2). Be sure to compensate for frame angle where required. 6. Determine the positive camber (2) or negative camber (3) angle. 7. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 8. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice in Service Precautions. 9. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met.When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. ^ Tighten the cam nuts to 190 Nm (140 ft. lbs.). 10. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications. When the caster and camber are within specifications, adjust the toe. Refer to Front Toe Adjustment. Front Toe Adjustment Front Toe Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 13265 1. Loosen the jam nut on the tie rod (2). 2. Rotate the inner tie rod (1) to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 68 Nm (50 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Rear Toe Adjustment Rear Toe Adjustment 1. Loosen the jam nut on the tie rod (1). 2. Rotate the inner tie rod to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 65 Nm (48 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams Steering Control Module: Diagrams Rear Wheel Steering Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 13271 Rear Wheel Steering Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 13272 Rear Wheel Steering Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 13273 Rear Wheel Steering Module - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 13276 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering Lifting and Jacking Notice in Service Precautions. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Connect the electrical connectors to the module. 4. Program the control module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 13277 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering). See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Rear Wheel Steering Switch > Component Information > Diagrams Rear Wheel Steering Mode Select Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Rear Wheel Steering Switch > Component Information > Diagrams > Page 13292 Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 13297 Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 13298 Rear Wheel Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 13299 Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering, Vehicle Lifting. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the electrical connector (1). 3. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 4. Remove the rear wheel position sensor retaining bolts (3). 5. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. Refer to Steering Gear Actuator and Cover Replacement. 6. Important: Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 13300 Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Lower the vehicle. 7. Perform a four wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13305 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13306 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13307 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13308 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13309 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13310 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13311 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13312 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13313 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 13319 Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 13320 Rear Wheel Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 13321 Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering, Vehicle Lifting. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the electrical connector (1). 3. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 4. Remove the rear wheel position sensor retaining bolts (3). 5. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. Refer to Steering Gear Actuator and Cover Replacement. 6. Important: Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 13322 Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Lower the vehicle. 7. Perform a four wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams > Page 13326 Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 13332 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair Center Link: Service and Repair Relay Rod Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller - J 29193 Steering Linkage Installer (12 mm) - J 29194 Steering Linkage Installer (14 mm) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Remove the steering damper from the relay rod, if equipped. Refer to Steering Damper Replacement. 4. Important: Use the proper tool in order to separate all the tie rod and the ball joints. Remove the tie rod ends (6). Refer to Tie Rod Replacement. 5. Remove the idler arm ball stud nut (10).Do not reuse the nut. 6. Remove the pitman arm nut (8).Do not reuse the nut. 7. Remove the relay rod from the idler arm ball stud using the J 24319-B. 8. Remove the relay rod from the pitman arm ball stud using the J 24319-B. 9. Remove the relay rod from the vehicle. 10. Inspect the threads on the tie rod ends for damage. 11. Inspect the ball stud threads for damage. 12. Inspect the ball stud seals for excessive damage. 13. Clean the threads on the ball studs. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 13337 1. Install the relay rod (9) to the vehicle. 2. Install the relay rod (9) to the pitman arm ball stud (2). 3. Install the relay rod (9) to the idler arm ball stud (1). 4. Ensure the seal is on the stud. 5. Install the J 29193 or the J 29194. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the steering linkage installer in order to seat the tapers. ^ Tighten the steering linkage installer to 54 Nm (40 ft. lbs.). 7. Remove the J 29193 or the J 29194. 8. Install the new pitman arm prevailing torque nut. 9. Install the new idler arm prevailing torque nut. ^ Tighten the nuts to 62 Nm (46 ft. lbs.). 10. Install the tie rod ends. Refer to Tie Rod Replacement. 11. Install the steering damper to the relay rod, if equipped. Refer to Steering Damper Replacement. 12. Install the engine protection shield, if equipped. 13. Lower the vehicle. 14. Check the wheel alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear Wheel Steering Front Steering Knuckle: Service and Repair Rear Wheel Steering Steering Knuckle Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller Removal Procedure Notice: Refer to Rear Wheel Steering Lifting and Jacking Notice in Service Precautions. 1. Remove the upper ball joint. 2. Remove the lower ball joint. 3. Remove the wheel hub and bearing. 4. Remove the outer tie rod retaining nut (1). 5. Disconnect the outer tie rod from the steering knuckle using the J 24319-B (1). 6. Remove the park brake cable retaining bolt (3) from the steering knuckle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear Wheel Steering > Page 13342 7. Remove the steering knuckle (2) from the vehicle. Installation Procedure 1. Install the steering knuckle (2) to the vehicle. 2. Install the upper ball joint. 3. Install the lower ball joint. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake cable retaining bolt (3) to the steering knuckle. ^ Tighten the bolt to 65 Nm (48 ft. lbs.). 5. Install the wheel hub and bearing. 6. Install the outer tie rod retaining nut (1). ^ Tighten the nut to 55 Nm (40 ft. lbs.). 7. Install the tire and wheel. 8. Perform a four wheel alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear Wheel Steering > Page 13343 Front Steering Knuckle: Service and Repair Front Steering Knuckle Replacement (4WD) ^ Tools Required ^ J 43631 Ball Joint Remover ^ J 45851 Ball Joint Separator Protector Adapters Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 4. Support the lower control arm with a suitable jack. 5. Disconnect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non- Rack and Pinion). 6. Remove the brake hose bracket retaining bolt from the steering knuckle. 7. Remove the upper control arm retaining nut and separate the upper ball joint from the steering knuckle using the J 43631 and J 45851. 8. Remove the lower control arm retaining nut. Separate the lower ball joint from the steering knuckle using the J 43631 and J 45851. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear Wheel Steering > Page 13344 9. Remove the steering knuckle. Installation Procedure 1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end. 2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, replace the steering knuckle. 3. Install the steering knuckle. 4. Notice: Refer to Fastener Notice in Service Precautions. Connect the lower ball joint to the steering knuckle and install the retaining nut. ^ Tighten the lower control arm retaining nut to 100 Nm (74 ft. lbs.). 5. Connect the upper ball joint to the steering knuckle and install the retaining nut. ^ Tighten the upper control arm retaining nut to 50 Nm (37 ft. lbs.). 6. Install the brake hose and the bracket retaining bolt to the steering knuckle ^ Tighten the bolt to 9 Nm (80 inch lbs.). 7. Connect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non-Rack and Pinion). 8. Install the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 9. Install the tire and wheel. 10. Remove the lower control arm support. 11. Lower the vehicle. 12. Align the vehicle. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear Wheel Steering > Page 13345 Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection Idler Arm: Testing and Inspection Idler Arm Inspection ^ Tools Required J 35999 Spring Scale - J 42640 Steering Column Anti-Rotation Pin - J 45101 Hub and Wheel Runout Gage 1. Raise the vehicle on a hoist. Support the vehicle with jackstands. Refer to Lifting and Jacking the Vehicle. 2. Position the wheels in a straight-ahead position and install the J 42640. Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. 3. Install the dial indicator J 45101 between the idler arm and vehicle frame. Ensure the gage is at zero before taking a measurement. 4. Place a J 35999 near the relay rod end of the idler arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 13349 5. Exert a 110 Nm (25 lb) force upward, and then downward while measuring the total distance the arm moves. 6. If movement exceeds 2 mm (0.078 inch) replace the idler arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 13350 7. Install the dial indicator at the idler arm. 8. Push the tire inward slowly with one hand to remove any lash. Zero out the dial indicator and pull outward in order to take a reading. 9. Allow only 1 mm (0.039 inch) of movement at the idler arm ball stud. If more than 1 mm exists, replace the idler arm. 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 13351 Idler Arm: Service and Repair Idler Arm Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller - J 29193 Steering Linkage Installer (12 mm) - J 29194 Steering Linkage Installer (14 mm) Removal Procedure Notice: Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Remove the idler arm ball stud nut (10).Do not reuse the idler arm ball stud nut. 4. Remove the idler arm from the relay rod using the J 24319-B. 5. Remove the idler arm frame bolts (3) and the nuts (1). 6. Remove the idler arm (2) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 13352 1. Position the idler arm (2) on the frame. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the frame bolts (3) and the nuts (1) to the idler arm. ^ Tighten the frame bolts or nuts to 99 Nm (73 ft. lbs.). 3. Install the relay rod (9) to the idler arm ball stud (1). Ensure the seal is on the stud. 4. Use the J 29193 in order to seat the tapers. ^ Tighten the J 29193 or the J 29194 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 5. Install the new idler arm ball stud prevailing torque nut to the idler arm ball stud. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 6. Install the engine protection shield, if equipped. 7. Lower the vehicle. 8. Check the wheel alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Steering/Suspension - Pitman Arm Shaft Seal Service Kit Pitman Arm: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 13357 Pitman Arm: Service and Repair Pitman Arm Replacement ^ Tools Required J 6632-01 Pitman Arm Puller - J 29107-A Pitman Arm Puller Removal Procedure 1. Raise and suitable support the vehicle. Refer to Vehicle Lifting. 2. Remove the power steering gear. Refer to Power Steering Gear Replacement (Rack and Pinion) Power Steering Gear Replacement (Non Rack and Pinion) in Power Steering System. 3. Install the power steering gear into a vise. 4. Remove the pitman arm nut and washer. 5. Remove the pitman arm from the pitman shaft using J 6632-01 or J 29107-A. Installation Procedure 1. Install the pitman arm to the power steering gear. 2. Notice: Refer to Fastener Notice in Service Precautions. Install a new pitman arm washer and nut. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 13358 ^ Tighten the nut to 250 Nm (184 ft. lbs.). 3. Remove the power steering gear from the vise. 4. Install the power steering gear. Refer to Power Steering Gear Replacement (Rack and Pinion) Power Steering Gear Replacement (Non Rack and Pinion) in Power Steering System. 5. Lower the vehicle. 6. Check the wheel alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Bleeding Important: - Use clean, new power steering fluid type only. See: Maintenance - Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not touch any other part of the vehicle. - Loose connections may not leak, but could allow air into the steering system. Verify that all hose connections are tight. - Power steering fluid level must be maintained throughout bleed procedure. 1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark on cap stick fluid level indicator. Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will discharge the hydro-boost accumulator. 2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following procedure: 2.1 Start the engine. 2.2 Firmly apply the brake pedal 10-15 times. 2.3 Turn the engine OFF. 3. Raise the vehicle until the front wheels are off the ground. See: Wheels and Tires/Vehicle Lifting 4. Key on engine OFF, turn the steering wheel from stop to stop 12 times. - Vehicle equipped with hydro-boost systems or longer length power steering hoses may require turns up to 15 to 20 stop to stops. 5. Verify power steering fluid level per operation specification. See: Power Steering Fluid 6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid aeration (pump noise/whining). 7. Verify the fluid level. Repeat the bleed procedure, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Information not provided by the manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 13367 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair Power Steering Reservoir Replacement - Off Vehicle Disassembly Procedure 1. Drain the power steering fluid from the power steering pump. 2. Remove the pump mounting studs (2). 3. Remove the connector and fitting assembly (5). To remove the variable assist steering actuator (3) and retaining ring (4). 4. Remove the O-ring seal (6) from the connector and fitting assembly (4). 5. If replacement is required, remove the control valve assembly and the flow control spring from the pump housing assembly; 6. Remove the reservoir assembly (1) from the pump housing assembly (2). 7. Remove the O-ring seals (1) (4). 8. Remove the magnet (3). 9. Clean the magnet (3). 10. Inspect the welch plug in the power steering pump housing (2). Do not remove. If the welch plug is deformed or dislodged, replace the power steering pump housing (2). Assembly Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 13371 1. Lubricate the O-ring seals (1) (4) with power steering fluid. Important: Use new O-ring seals when assembling the power steering pump assembly. 2. To install the control valve assembly and flow control spring to the pump housing assembly (2); 3. Install the O-ring seals (1) (4) to the pump housing assembly (2). 4. Install the magnet (3) to the pump housing assembly (2). 5. Connect the reservoir assembly (1) to the pump housing assembly (2). 6. Install the O-ring seal. 7. Install the connector and fitting assembly (5). To install the variable assist steering actuator (3) and retaining ring (4). Notice: Refer to Fastener Notice in Service Precautions. 8. Install the pump mounting studs (2) to the pump housing (1). ^ Tighten the pump mounting studs (2) to 58 Nm (43 ft. lbs.). ^ Tighten the connector and fitting assembly (5) to 75 Nm (55 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures Technical Service Bulletin # 05086A Date: 051116 Recall - Power Steering Hose Fractures Product Safety - Power Steering Hose Fracture # 05086A - (Nov 16, 2005) Models: 2006 BUICK RAINIER 2006 CADILLAC ESCALADE 2005 CHEVROLET CORVETTE, SILVERADO 2006 CHEVROLET CORVETTE, EXPRESS, SILVERADO, TAHOE, TRAILBLAZER, TRAILBLAZER EXT 2005 GMC SIERRA 2006 GMC ENVOY, ENVOY XL, SAVANA, SIERRA, YUKON 2006 HUMMER H2 ALSO USED AS A SERVICE PART (18 PART NUMBERS INVOLVED) This bulletin is being revised to address hoses used to service 1991-2006 vehicles. Dealers who ordered these hoses for service are identified in the attachment contained in the Administrative Message (U.S.) or Dealer Communication (Canada). Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles. Some of these vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with hydro-boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. Note: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991-2006 vehicles. Correction Dealers are to inspect the power steering hose(s) for two suspect date codes and replace them if required. Dealers who have ordered the involved hoses for service (see listing in Administrative Message) are to search their part sales records to determine the name and address of the purchaser(s). If the purchaser is the owner of the vehicle, dealers are to send the owner a copy of the appropriate letter shown in this bulletin requesting them to bring their vehicle in for repair. If the purchaser is a body shop, independent repair shop, etc., dealers are to send the shop a copy of the appropriate letter shown in this bulletin requesting that they provide the customer's name, address, and telephone number so the dealer can send the owner a copy of the letter. Vehicles Involved Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13380 Involved are certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991 - 2006 vehicles. Affected dealers have already been issued a Special Return Bulletin to return any shelf stock, refer to Administrative Message VSU20050801 - GMP05 -157. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Dealers that have ordered involved hoses for service will also be listed in the report contained in the Administrative Message. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete vehicle identification number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Less than 10% of the involved vehicles will require hose replacement. If parts are required, order the appropriate hose(s) from General Motors Service Parts Operations (GMSPO). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Claim Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13381 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13382 Submit a Product Recall claim with the information shown. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). For vehicles with the recalled component installed on their vehicles outside of warranty, dealers are to notify customers of this recall using a copy of the letter shown in this bulletin. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possession The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13383 Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Following this customer letter is another letter for customers identified through dealer search retype this letter and insert the appropriate information. Disclaimer Service Procedure Inspection Procedure 1. Inspect and record the power steering pressure line for the date code as shown above. The date code is printed on the hose and is repeated approximately every 6 inches (150 mm). Depending on the vehicle configuration, there may be one or two hoses to inspect. Vehicles equipped with the hydro-boost system will have two hoses while others will only have one hose. Removal of conduit may be necessary in order to inspect the date code. 2. Rainier/TrailBlazer/TrailBlazer EXT/Envoy/Envoy XL with 4.2L Engine Power Steering Pressure Hose (1). This pressure line has two hose sections and both must be inspected. Vehicle may need to be lifted to inspect both. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13384 3. Express/Savana Steering Pump to Hydro-Boost Pressure Line (2). 4. Express/Savana Hydro-Boost to Steering Gear Pressure Line (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13385 5. Silverado/Tahoe/Sierra/Yukon/Escalade Non Hydro-Boost Pressure Line (3). 6. Silverado/Tahoe/Sierra/Yukon/Escalade Power Steering Pump to Hydro-Boost Pressure Line (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13386 7. Silverado/Tahoe/Sierra/Yukon/Escalade Hydro-Boost to Steering Gear Pressure Line (1). 8. Hummer H2 Power Steering Pump to Hydro-Boost Pressure Line. 9. Hummer H2 Hydro-Boost to Steering Gear Pressure Line. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13387 10. Corvette Power Steering Pressure Hose (2). The vehicle will need to be lifted on a hoist for inspection. Removal of the power steering cooler bolts will give increased access to the pressure hose. 11. Compare the date code on the hose(s) to the suspect date codes shown. - If the date code is one of the codes listed, the hose(s) must be replaced. Proceed to the Hose Replacement Procedure. - If the date code is not one of the codes shown, then replace the conduit if applicable and no further action is required. Hose Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13388 If the inspection reveals that the hose needs to be replaced, follow the instructions in SI. Shown are the SI document numbers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13389 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13390 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13391 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13392 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13393 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V455000 > Oct > 05 > Recall 05V455000: Power Steering Hose Fracturing Power Steering Line/Hose: Recalls Recall 05V455000: Power Steering Hose Fracturing MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2006 Cadillac/Escalade 2006 Chevrolet/Corvette 2005-2006 Chevrolet/Express 2006 Chevrolet/Silverado 2005-2006 Chevrolet/Tahoe 2006 Chevrolet/Trailblazer 2006 Chevrolet/Trailblazer EXT 2006 GMC/Envoy 2006 GMC/Envoy XL 2006 GMC/Savana 2006 GMC/Sierra 2005-2006 GMC/Yukon 2006 Hummer/H2 2006 Isuzu/Ascender 2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V455000 MFG'S REPORT DATE: October 04, 2005 COMPONENT: Steering: Hydraulic Power Assist: Hose, Piping, and Connections POTENTIAL NUMBER OF UNITS AFFECTED: 123592 SUMMARY: Certain passenger vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. CONSEQUENCE: If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with Hydro-Boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. REMEDY: Dealers will inspect the power steering hose(s) for two suspect date codes and replace them if required. The recall will begin on October 14, 2005. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Buick at 1-866-608-8080, Cadillac at 1-866-982-2339, Isuzu at 1-800-255-6727, or HUMMER at 1-800-732-5493. NOTES: GM recall No. 05086. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 13403 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 13404 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 13405 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 13406 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures Technical Service Bulletin # 05086A Date: 051116 Recall - Power Steering Hose Fractures Product Safety - Power Steering Hose Fracture # 05086A - (Nov 16, 2005) Models: 2006 BUICK RAINIER 2006 CADILLAC ESCALADE 2005 CHEVROLET CORVETTE, SILVERADO 2006 CHEVROLET CORVETTE, EXPRESS, SILVERADO, TAHOE, TRAILBLAZER, TRAILBLAZER EXT 2005 GMC SIERRA 2006 GMC ENVOY, ENVOY XL, SAVANA, SIERRA, YUKON 2006 HUMMER H2 ALSO USED AS A SERVICE PART (18 PART NUMBERS INVOLVED) This bulletin is being revised to address hoses used to service 1991-2006 vehicles. Dealers who ordered these hoses for service are identified in the attachment contained in the Administrative Message (U.S.) or Dealer Communication (Canada). Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles. Some of these vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with hydro-boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. Note: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991-2006 vehicles. Correction Dealers are to inspect the power steering hose(s) for two suspect date codes and replace them if required. Dealers who have ordered the involved hoses for service (see listing in Administrative Message) are to search their part sales records to determine the name and address of the purchaser(s). If the purchaser is the owner of the vehicle, dealers are to send the owner a copy of the appropriate letter shown in this bulletin requesting them to bring their vehicle in for repair. If the purchaser is a body shop, independent repair shop, etc., dealers are to send the shop a copy of the appropriate letter shown in this bulletin requesting that they provide the customer's name, address, and telephone number so the dealer can send the owner a copy of the letter. Vehicles Involved Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13416 Involved are certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991 - 2006 vehicles. Affected dealers have already been issued a Special Return Bulletin to return any shelf stock, refer to Administrative Message VSU20050801 - GMP05 -157. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Dealers that have ordered involved hoses for service will also be listed in the report contained in the Administrative Message. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete vehicle identification number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Less than 10% of the involved vehicles will require hose replacement. If parts are required, order the appropriate hose(s) from General Motors Service Parts Operations (GMSPO). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Claim Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13417 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13418 Submit a Product Recall claim with the information shown. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). For vehicles with the recalled component installed on their vehicles outside of warranty, dealers are to notify customers of this recall using a copy of the letter shown in this bulletin. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possession The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13419 Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Following this customer letter is another letter for customers identified through dealer search retype this letter and insert the appropriate information. Disclaimer Service Procedure Inspection Procedure 1. Inspect and record the power steering pressure line for the date code as shown above. The date code is printed on the hose and is repeated approximately every 6 inches (150 mm). Depending on the vehicle configuration, there may be one or two hoses to inspect. Vehicles equipped with the hydro-boost system will have two hoses while others will only have one hose. Removal of conduit may be necessary in order to inspect the date code. 2. Rainier/TrailBlazer/TrailBlazer EXT/Envoy/Envoy XL with 4.2L Engine Power Steering Pressure Hose (1). This pressure line has two hose sections and both must be inspected. Vehicle may need to be lifted to inspect both. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13420 3. Express/Savana Steering Pump to Hydro-Boost Pressure Line (2). 4. Express/Savana Hydro-Boost to Steering Gear Pressure Line (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13421 5. Silverado/Tahoe/Sierra/Yukon/Escalade Non Hydro-Boost Pressure Line (3). 6. Silverado/Tahoe/Sierra/Yukon/Escalade Power Steering Pump to Hydro-Boost Pressure Line (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13422 7. Silverado/Tahoe/Sierra/Yukon/Escalade Hydro-Boost to Steering Gear Pressure Line (1). 8. Hummer H2 Power Steering Pump to Hydro-Boost Pressure Line. 9. Hummer H2 Hydro-Boost to Steering Gear Pressure Line. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13423 10. Corvette Power Steering Pressure Hose (2). The vehicle will need to be lifted on a hoist for inspection. Removal of the power steering cooler bolts will give increased access to the pressure hose. 11. Compare the date code on the hose(s) to the suspect date codes shown. - If the date code is one of the codes listed, the hose(s) must be replaced. Proceed to the Hose Replacement Procedure. - If the date code is not one of the codes shown, then replace the conduit if applicable and no further action is required. Hose Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13424 If the inspection reveals that the hose needs to be replaced, follow the instructions in SI. Shown are the SI document numbers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13425 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13426 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13427 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13428 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13429 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 02-06-04-037I > Sep > 10 > Recalls for Power Steering Line/Hose: > NHTSA05V455000 > Oct > 05 > Recall 05V455000: Power Steering Hose Fracturing Power Steering Line/Hose: Recalls Recall 05V455000: Power Steering Hose Fracturing MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2006 Cadillac/Escalade 2006 Chevrolet/Corvette 2005-2006 Chevrolet/Express 2006 Chevrolet/Silverado 2005-2006 Chevrolet/Tahoe 2006 Chevrolet/Trailblazer 2006 Chevrolet/Trailblazer EXT 2006 GMC/Envoy 2006 GMC/Envoy XL 2006 GMC/Savana 2006 GMC/Sierra 2005-2006 GMC/Yukon 2006 Hummer/H2 2006 Isuzu/Ascender 2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V455000 MFG'S REPORT DATE: October 04, 2005 COMPONENT: Steering: Hydraulic Power Assist: Hose, Piping, and Connections POTENTIAL NUMBER OF UNITS AFFECTED: 123592 SUMMARY: Certain passenger vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. CONSEQUENCE: If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with Hydro-Boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. REMEDY: Dealers will inspect the power steering hose(s) for two suspect date codes and replace them if required. The recall will begin on October 14, 2005. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Buick at 1-866-608-8080, Cadillac at 1-866-982-2339, Isuzu at 1-800-255-6727, or HUMMER at 1-800-732-5493. NOTES: GM recall No. 05086. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures Technical Service Bulletin # 05086A Date: 051116 Recall - Power Steering Hose Fractures Product Safety - Power Steering Hose Fracture # 05086A - (Nov 16, 2005) Models: 2006 BUICK RAINIER 2006 CADILLAC ESCALADE 2005 CHEVROLET CORVETTE, SILVERADO 2006 CHEVROLET CORVETTE, EXPRESS, SILVERADO, TAHOE, TRAILBLAZER, TRAILBLAZER EXT 2005 GMC SIERRA 2006 GMC ENVOY, ENVOY XL, SAVANA, SIERRA, YUKON 2006 HUMMER H2 ALSO USED AS A SERVICE PART (18 PART NUMBERS INVOLVED) This bulletin is being revised to address hoses used to service 1991-2006 vehicles. Dealers who ordered these hoses for service are identified in the attachment contained in the Administrative Message (U.S.) or Dealer Communication (Canada). Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles. Some of these vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with hydro-boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur. Note: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991-2006 vehicles. Correction Dealers are to inspect the power steering hose(s) for two suspect date codes and replace them if required. Dealers who have ordered the involved hoses for service (see listing in Administrative Message) are to search their part sales records to determine the name and address of the purchaser(s). If the purchaser is the owner of the vehicle, dealers are to send the owner a copy of the appropriate letter shown in this bulletin requesting them to bring their vehicle in for repair. If the purchaser is a body shop, independent repair shop, etc., dealers are to send the shop a copy of the appropriate letter shown in this bulletin requesting that they provide the customer's name, address, and telephone number so the dealer can send the owner a copy of the letter. Vehicles Involved Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13439 Involved are certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991 - 2006 vehicles. Affected dealers have already been issued a Special Return Bulletin to return any shelf stock, refer to Administrative Message VSU20050801 - GMP05 -157. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Dealers that have ordered involved hoses for service will also be listed in the report contained in the Administrative Message. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete vehicle identification number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Less than 10% of the involved vehicles will require hose replacement. If parts are required, order the appropriate hose(s) from General Motors Service Parts Operations (GMSPO). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Claim Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13440 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13441 Submit a Product Recall claim with the information shown. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). For vehicles with the recalled component installed on their vehicles outside of warranty, dealers are to notify customers of this recall using a copy of the letter shown in this bulletin. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possession The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13442 Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Following this customer letter is another letter for customers identified through dealer search retype this letter and insert the appropriate information. Disclaimer Service Procedure Inspection Procedure 1. Inspect and record the power steering pressure line for the date code as shown above. The date code is printed on the hose and is repeated approximately every 6 inches (150 mm). Depending on the vehicle configuration, there may be one or two hoses to inspect. Vehicles equipped with the hydro-boost system will have two hoses while others will only have one hose. Removal of conduit may be necessary in order to inspect the date code. 2. Rainier/TrailBlazer/TrailBlazer EXT/Envoy/Envoy XL with 4.2L Engine Power Steering Pressure Hose (1). This pressure line has two hose sections and both must be inspected. Vehicle may need to be lifted to inspect both. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13443 3. Express/Savana Steering Pump to Hydro-Boost Pressure Line (2). 4. Express/Savana Hydro-Boost to Steering Gear Pressure Line (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13444 5. Silverado/Tahoe/Sierra/Yukon/Escalade Non Hydro-Boost Pressure Line (3). 6. Silverado/Tahoe/Sierra/Yukon/Escalade Power Steering Pump to Hydro-Boost Pressure Line (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13445 7. Silverado/Tahoe/Sierra/Yukon/Escalade Hydro-Boost to Steering Gear Pressure Line (1). 8. Hummer H2 Power Steering Pump to Hydro-Boost Pressure Line. 9. Hummer H2 Hydro-Boost to Steering Gear Pressure Line. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13446 10. Corvette Power Steering Pressure Hose (2). The vehicle will need to be lifted on a hoist for inspection. Removal of the power steering cooler bolts will give increased access to the pressure hose. 11. Compare the date code on the hose(s) to the suspect date codes shown. - If the date code is one of the codes listed, the hose(s) must be replaced. Proceed to the Hose Replacement Procedure. - If the date code is not one of the codes shown, then replace the conduit if applicable and no further action is required. Hose Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13447 If the inspection reveals that the hose needs to be replaced, follow the instructions in SI. Shown are the SI document numbers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13448 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13449 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13450 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13451 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > 05086A > Nov > 05 > Recall - Power Steering Hose Fractures > Page 13452 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > NHTSA05V455000 > Oct > 05 > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > NHTSA05V455000 > Oct > 05 > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 13461 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > NHTSA05V455000 > Oct > 05 > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 13462 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > NHTSA05V455000 > Oct > 05 > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 13463 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Volume Control Valve: > NHTSA05V455000 > Oct > 05 > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 13464 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13470 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13471 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13472 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13473 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13474 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13475 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13476 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13477 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13478 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13479 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13480 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13481 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13482 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13483 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13484 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13485 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13486 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13487 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13488 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13489 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13490 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13491 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13492 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13493 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13494 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13495 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13496 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13497 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13498 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13499 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13500 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13501 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13502 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13503 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13504 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13505 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13506 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13507 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13508 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13509 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13510 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13511 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13512 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13513 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13514 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13515 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13516 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13517 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13518 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13519 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13520 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13521 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13522 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13523 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13524 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13525 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13526 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13527 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13528 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13529 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13530 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13531 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13532 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13533 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13534 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13535 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13536 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13537 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13538 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13539 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13540 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13541 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13542 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13543 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13544 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13545 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Diagram Information and Instructions > Page 13546 Crankshaft Position (CKP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Diagrams > Page 13547 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release throttle when fuel cut-off occurs. 8. The scan tool display reads Test In Progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 13550 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 13551 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular) Power Steering Pressure Control Valve: Service and Repair Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular) Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular) Disassembly Procedure 1. Drain the oil from the reservoir (1). 2. Remove the control valve assembly (3) from the pump housing (1). Make sure the flow control spring (4) does not fall out of the pump housing (1). 3. Remove the rectangular section seal (2) from the control valve assembly (3). Assembly Procedure 1. Install the flow control spring (4) if removed from the pump housing (1). 2. Lubricate the new rectangular section seal (2) with power steering fluid. 3. Install the rectangular section seal (2) onto the control valve assembly (3). 4. Install the control valve assembly (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular) > Page 13560 Power Steering Pressure Control Valve: Service and Repair Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle Disassembly Procedure 1. Remove the electrical connector from the variable assist steering actuator (1). 2. Remove pump assembly from the vehicle, if the variable assist steering actuator (1) is not accessible. 3. Remove the retaining ring (2) from the variable assist steering actuator (1). 4. Remove the variable assist steering actuator (1). Important: Note the orientation of the variable assist steering actuator discharge fitting. 5. Remove the O-ring seal from the variable assist steering actuator. Assembly Procedure 1. Lubricate and install the new O-ring seal with power steering fluid. Important: Note the orientation of the variable assist steering actuator discharge fitting. 2. Install the variable assist steering actuator (1) to the pump assembly. ^ Tighten the actuator to 62 Nm (46 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the negative battery cable. 4. Install the electrical connector to the variable assist steering actuator (1). Important: If a new variable assist steering actuator (1) is being installed, position the electrical connector before installing the retaining ring (2). 5. Install the retaining ring (2) to the variable assist steering actuator (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Power Steering Pump Seal > Component Information > Service and Repair Power Steering Pump Seal: Service and Repair Power Steering Pump Drive Shaft Seal Replacement Removal Procedure 1. Remove the power steering pump from the vehicle. 2. Use a chisel in order to cut and remove the seal. Important: Use the shim stock in order to protect the drive shaft. Installation Procedure 1. Lubricate the seal using power steering fluid. 2. Use a deep 1 inch tall socket in order to install the seal. 3. Install the power steering pump. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams Steering Control Module: Diagrams Rear Wheel Steering Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Page 13568 Rear Wheel Steering Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Page 13569 Rear Wheel Steering Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Page 13570 Rear Wheel Steering Module - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 13573 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering Lifting and Jacking Notice in Service Precautions. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Connect the electrical connectors to the module. 4. Program the control module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 13574 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering). See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Page 13577 Rear Wheel Steering Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Page 13578 Rear Wheel Steering Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Page 13579 Rear Wheel Steering Module - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 13582 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering Lifting and Jacking Notice in Service Precautions. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Connect the electrical connectors to the module. 4. Program the control module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 13583 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering). See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Actuator > Component Information > Service and Repair > Steering Gear Actuator Boot Shield Replacement Rear Wheel Steering Actuator: Service and Repair Steering Gear Actuator Boot Shield Replacement Steering Gear Actuator Boot Shield Replacement Removal Procedure 1. Notice: When lifting the vehicle do not allow the jack to touch the rear steering gear. If the jack touches the rear steering gear you may damage the gear or the rack and pinion boots. If the boots are damaged replace the rack and pinion boot. Raise the vehicle. Refer to Vehicle Lifting. 2. Unsnap the locking tabs on the rack and pinion boot protector (1). 3. Remove the rack and pinion boot protector (1) from the rack and pinion boot (2). Installation Procedure 1. Install the rack and pinion boot protector (1) to the rack and pinion boot (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Actuator > Component Information > Service and Repair > Steering Gear Actuator Boot Shield Replacement > Page 13589 2. Snap the locking tabs together on the rack and pinion boot protector. 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Actuator > Component Information > Service and Repair > Steering Gear Actuator Boot Shield Replacement > Page 13590 Rear Wheel Steering Actuator: Service and Repair Steering Gear Actuator and Cover Replacement Steering Gear Actuator and Cover Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the drain plug (2) and drain the fluid from the differential housing. 4. Remove the bolts (3) retaining the steering gear protection shield. 5. Disconnect the electrical connectors from the control module (2). 6. Disconnect the electrical connector (1) from the rear position sensor. 7. Remove the outer tie rod ends from the steering knuckle. Refer to Rear Wheel Steering Tie Rod End Replacement - Outer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Actuator > Component Information > Service and Repair > Steering Gear Actuator Boot Shield Replacement > Page 13591 8. Disconnect the differential vent hose (1) from the vent tube (2). 9. Remove the bolts retaining the steering gear actuator and cover (2) to the differential (1). 10. Remove the steering gear actuator and cover from the vehicle. Installation Procedure 1. Important: Clean all of the sealing surfaces prior to installing the gasket. Do not reinstall the old gasket, replace the gasket whenever the actuator is removed from the axle. Install the steering gear actuator (2) and gasket (1) to the differential. 2. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Actuator > Component Information > Service and Repair > Steering Gear Actuator Boot Shield Replacement > Page 13592 Install the steering gear actuator and cover (2) retaining bolts. ^ Tighten the bolts to 61 Nm (45 ft. lbs.). 3. Connect the electrical connectors to the control module (2). 4. Install the differential vent hose (1) to the vent tube (2). 5. Install the outer tie rod ends to the steering knuckle. Refer to Rear Wheel Steering Tie Rod End Replacement - Outer. 6. Install the drain plug (2) and fill the differential with fluid. 7. Install the bolts (3) retaining the steering gear protection shield. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 8. Install the tire and wheel. 9. Lower the vehicle. 10. Check the wheel alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Switch > Component Information > Diagrams Rear Wheel Steering Mode Select Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Switch > Component Information > Diagrams > Page 13596 Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams Steering Control Module: Diagrams Rear Wheel Steering Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 13601 Rear Wheel Steering Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 13602 Rear Wheel Steering Control Module - C3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 13603 Rear Wheel Steering Module - C4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 13606 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering Lifting and Jacking Notice in Service Precautions. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Connect the electrical connectors to the module. 4. Program the control module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 13607 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering). See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Rear Wheel Steering Switch > Component Information > Diagrams Rear Wheel Steering Mode Select Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Rear Wheel Steering Switch > Component Information > Diagrams > Page 13612 Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 13617 Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 13618 Rear Wheel Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 13619 Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering, Vehicle Lifting. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the electrical connector (1). 3. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 4. Remove the rear wheel position sensor retaining bolts (3). 5. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. Refer to Steering Gear Actuator and Cover Replacement. 6. Important: Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 13620 Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Lower the vehicle. 7. Perform a four wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13625 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13626 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13627 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13628 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13629 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13630 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13631 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13632 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13633 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 13638 Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 13639 Rear Wheel Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams > Page 13640 Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering, Vehicle Lifting. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the electrical connector (1). 3. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 4. Remove the rear wheel position sensor retaining bolts (3). 5. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. Refer to Steering Gear Actuator and Cover Replacement. 6. Important: Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams > Page 13641 Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Lower the vehicle. 7. Perform a four wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 13647 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both front end sensor connectors (2) located on the frame crossmember (1). IMPORTANT: This vehicle is equipped with two inflatable restraint front end sensors. When performing this procedure be sure to include both front end sensors. 7. Disconnect both front end sensor connectors (2). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the front end sensor connectors (2) to both front end sensors. 3. Install the CPAs to both front end sensor connectors (2). 4. Install the SIR fuse into the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 13648 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 6. Disconnect the steering wheel module yellow 4-way connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 13649 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) from the instrument panel (I/P) module yellow 4-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 4-way connector (1). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the I/P module yellow 4-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 4-way connector (1). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 13650 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both front end sensor connectors (2) located on the frame crossmember (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 13651 IMPORTANT: This vehicle is equipped with two inflatable restraint front end sensors. When performing this procedure be sure to include both front end sensors. 7. Disconnect both front end sensor connectors (2). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the front end sensor connectors (2) to both front end sensors. 3. Install the CPAs to both front end sensor connectors (2). 4. Install the SIR fuse into the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 6. Disconnect the steering wheel module yellow 4-way connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 13652 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) from the instrument panel (I/P) module yellow 4-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 4-way connector (1). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the I/P module yellow 4-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 4-way connector (1). 4. Install the SIR fuse to the fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 13653 6. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 6 SIR DISABLING AND ENABLING ZONE 6 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the RF door trim panel. 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom right of the door (4). 7. Disconnect the side impact sensor yellow 2-way connector (5). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door (4). 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5). 4. Install the RF door trim panel. 5. Install the SIR fuse to the fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. SIR Disabling and Enabling Zone 7 SIR DISABLING AND ENABLING ZONE 7 DISABLING PROCEDURE 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 13654 4. Remove the SIR fuse from the fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 6. Disconnect the steering wheel module yellow 4-way connector (2). 7. Remove the CPA from the instrument panel (I/P) module yellow 4-way connector (1) located behind the I/P support. 8. Disconnect the I/P module yellow 4-way connector (1). ENABLING PROCEDURE 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2). 4. Connect the I/P module yellow 4-way connector (1) located behind the I/P support. 5. Install the CPA to the I/P module yellow 4-way connector (1). 6. Install the SIR fuse to the fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 1. The AIR BAG indicator will flash 7 times. 2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, if the AIR BAG indicator does not operate as described. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Column Bearing: Customer Interest Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13663 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13664 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13665 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Column Bearing: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13671 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13672 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13673 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13678 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13679 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13680 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13681 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13682 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13683 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13684 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13685 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 13686 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair Steering Damper: Service and Repair Steering Damper Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller - J 29193 Steering Linkage Installer-12 mm Removal Procedure 1. Raise the vehicle. Support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Important: Do not reuse the nut. Remove the steering damper (2) ball stud nut (1). 4. Remove the steering damper ball stud from the relay rod using the J 24319-B. 5. Important: Do not reuse the nut. Remove the steering damper mounting bolt (5) and the nut (6). 6. Remove the steering damper (4) from the vehicle. 7. Inspect the following parts: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair > Page 13690 ^ The steering damper for leaks and damage ^ The mounting bolts and the nuts for damage or corrosion Installation Procedure 1. Install the steering damper (4). 2. Install the mounting bolt (5) and a new prevailing torque nut (6). 3. Install the steering damper ball stud (2) to the relay rod (3). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the J 29193. 5. Tighten the steering linkage installer in order to seat the ball stud in the relay rod. ^ Tighten the installer to 54 Nm (40 ft. lbs.). 6. Remove the J 29193. 7. Install the prevailing torque nuts. ^ Tighten the steering damper mounting nut to 40 Nm (30 ft. lbs.). ^ Tighten the ball stud nut to 40 Nm (30 ft. lbs.). 8. Install the engine protection shield, if equipped. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Steering/Suspension - Pitman Arm Shaft Seal Service Kit Steering Gear Seal: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Page 13696 Steering Gear Seal: Service and Repair Steering Gear Stub Shaft Seals and Bearing Replacement - Off Vehicle ^ Tools Required J 29810 Stub Shaft Seal Protector Disassembly Procedure 1. Remove the steering gear from the vehicle, 2. Remove the adjuster plug lock nut (5) from the adjuster plug (4). 3. Remove the adjuster plug (4) from the gear assembly (1). 4. Remove the adjuster spring (3) and the rack bearing (2). 5. Remove the spool shaft boot (1) from the rack and pinion gear assembly. 6. Remove the retaining ring (2) from the valve bore of the rack and pinion gear assembly. 7. Remove the dust cover (4) from the bottom of the rack and pinion gear assembly. 8. Remove the hex lock nut (3) from the lower end of the pinion and valve assembly while holding the stub shaft with a 14 mm crowfoot wrench. 9. Using an arbor press (1), press on the threaded end of the pinion until removal of the following items is possible: 1. The stub shaft (4) 2. The stub shaft seal (2) 3. The stub shaft bearing annulus assembly (3) Important: When performing the following procedure, do not remove pinion and valve assembly from the rack and pinion gear assembly (5). Press the pinion and valve assembly only far enough to allow removal of the stub shaft bearing annulus (3) and the stub shaft seal (2). Assembly Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Page 13697 1. Install the hex lock nut (1) onto the pinion while holding the valve stub shaft. ^ Tighten the nut to 30 Nm (22 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the dust cover (2) to the rack and pinion gear assembly. 3. Install the stub shaft bearing annulus assembly (1) onto the valve stub shaft (2). 4. Install J 29810 onto the valve stub shaft. 5. Lubricate the stub shaft seal (3) with grease. 6. Install the stub shaft seal (3) into the rack and pinion gear assembly. 7. Install the retaining ring (2) into the groove in the rack and pinion gear assembly. 8. Install the spool shaft boot (1) onto the rack and pinion gear assembly. 9. Lubricate the following items with lithium base grease: 1. The rack bearing (2) 2. The adjuster spring (3) 3. The adjuster plug (4) 10. Install the following items into the gear assembly: 1. The rack bearing (2) 2. The adjuster spring (3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Page 13698 3. The adjuster plug (4) 11. Turn the adjuster plug (1) clockwise onto the rack and pinion gear assembly until the adjuster plug (1) bottoms in the rack and pinion gear assembly, then turn the adjuster plug (1) back 50 degrees to 70 degrees. 12. Check the rotational torque on the pinion. The maximum pinion preload torque is 1.8 Nm (16 inch lbs.). 13. Install the adjuster plug lock nut (5) to the adjuster plug (4).Finger tighten the adjuster plug lock nut (5) while holding the adjuster plug (4) stationary. ^ Tighten the nut to 68 Nm (50 ft. lbs.). 14. Install the steering gear into the vehicle, 15. Flush and bleed power the steering system (hoses, reservoir and cooler lines) with power steering fluid GM P/N 1050017 (Canadian P/N 992646) (or equivalent meeting GM Specification number 9985010). Important: Refer to Bleeding the Power Steering System. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13703 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13704 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13705 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13706 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13707 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13708 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13709 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13710 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13711 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13712 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13713 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13714 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13715 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13716 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13717 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13718 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13719 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13720 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13721 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13722 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13723 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13724 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13725 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13726 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13727 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13728 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13729 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13730 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13731 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13732 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13733 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13734 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13735 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13736 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13737 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13738 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13739 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13740 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13741 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13742 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13743 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13744 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13745 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13746 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13747 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13748 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13749 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13750 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13751 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13752 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13753 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13754 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13755 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13756 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13757 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13758 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13759 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13760 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13761 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13762 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13763 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13764 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13765 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13766 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13767 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13768 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13769 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13770 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13771 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13772 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13773 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13774 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13775 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13776 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13777 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13778 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13779 Steering Mounted Controls Transmitter: Connector Views Steering Wheel Driver Information Center (DIC) Controls - Left (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13780 Steering Wheel Driver Information Center (DIC) Controls - Right (With RPO Code YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 13781 Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement Removal Procedure 1. Remove the steering wheel. 2. Remove the shroud retaining screws from the back of the steering wheel. 3. Remove the shroud from the steering wheel. 4. Position a blunt ended tool into the wire harness cavity (1) and apply moderate pressure in order to partially remove the steering wheel control switch from the steering wheel. 5. Disconnect the steering wheel control switch electrical connector. 6. Important: The bulbs in the steering wheel control switches are not serviceable. The switches should be replaced only as an assembly. Remove the steering wheel control switch from the steering wheel. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 13782 1. Position the steering wheel control switch to the steering wheel. 2. Connect the electrical connector to the steering wheel control switch. 3. Install the steering wheel control switch into the steering wheel, ensuring the retaining tabs are fully seated. 4. Install the shroud to the steering wheel. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the shroud retaining screws to the steering wheel. ^ Tighten the screws to 2 Nm (18 inch lbs.). 6. Install the steering wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: Customer Interest Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13791 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13792 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13793 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning Steering Shaft: Customer Interest Body/Steering - Clunk Noise When Turning Bulletin No.: 05-02-35-003B Date: January 27, 2006 TECHNICAL Subject: EI05061 - Intermediate Steering Shaft Clunk Noise or Stick-Slip (Follow Strategy Based Diagnostics) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2006 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the diagnostic information. Please discard Corporate Bulletin Number 05-02-35-003A (Section 02 - Steering). Condition Some customers may comment on a "clunk" noise coming from the front of the vehicle. Correction Information has shown that the noise may be caused by the following three areas (listed in no particular order). Many of these concerns may initially be mis-diagnosed as an I-shaft clunk. ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined that the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined that the cause of the concern is the I-Shaft, follow the repair procedures/bulletins found in published Service Information (SI) concerning I-shaft lubing/replacement. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning > Page 13798 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 05-02-35-003 > Jun > 05 > Body/Steering - Clunk From Front of Vehicle on Turns Steering Shaft: Customer Interest Body/Steering - Clunk From Front of Vehicle on Turns Bulletin No.: 05-02-35-003 Date: June 03, 2005 ADVANCED SERVICE INFORMATION Subject: ADVANCED SERVICE INFORMATION - EI-05061 I-Shaft Clunk or Stick-Slip Models: 2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005 GMC Sierra, Yukon, Yukon XL Attention: THIS IS NOT A RECALL. "GM of Canada" dealers are not authorized to use this bulletin. This bulletin ONLY applies to vehicles in which the customer has commented about this concern AND the E1 number shows in GMVIS. All others should disregard this bulletin and proceed with diagnostics found in published service information. Condition Important: If the customer did not bring their vehicle in for this issue, DO NOT proceed with this bulletin. Customers may comment about a "clunk" noise coming from the front of the vehicle. Correction GM Engineering is attempting to determine the root cause of I-Shaft replacements. There are three potential areas that may cause the customer's concern. GM Engineering is requesting that the three areas be evaluated before making any repairs. The three areas (listed in no particular order) that may cause the customer's concern are: ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined the cause of the concern is the I-Shaft, contact the following engineers who will want to evaluate the vehicle: IF IT IS DETERMINED THE CAUSE OF THE CUSTOMER'S CONCERN IS THE I-SHAFT, DO NOT MAKE ANY REPAIRS. CONTACT ONE OF THE FOLLOWING ENGINEERS WHO WILL COME TO THE DEALERSHIP TO EVALUATE THE CONCERN AND PROVIDE THE TECHNICIAN WITH REPAIR INSTRUCTIONS. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 05-02-35-003 > Jun > 05 > Body/Steering - Clunk From Front of Vehicle on Turns > Page 13803 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13809 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13810 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 13811 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning Steering Shaft: All Technical Service Bulletins Body/Steering - Clunk Noise When Turning Bulletin No.: 05-02-35-003B Date: January 27, 2006 TECHNICAL Subject: EI05061 - Intermediate Steering Shaft Clunk Noise or Stick-Slip (Follow Strategy Based Diagnostics) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2006 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the diagnostic information. Please discard Corporate Bulletin Number 05-02-35-003A (Section 02 - Steering). Condition Some customers may comment on a "clunk" noise coming from the front of the vehicle. Correction Information has shown that the noise may be caused by the following three areas (listed in no particular order). Many of these concerns may initially be mis-diagnosed as an I-shaft clunk. ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined that the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined that the cause of the concern is the I-Shaft, follow the repair procedures/bulletins found in published Service Information (SI) concerning I-shaft lubing/replacement. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning > Page 13816 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 05-02-35-003 > Jun > 05 > Body/Steering - Clunk From Front of Vehicle on Turns Steering Shaft: All Technical Service Bulletins Body/Steering - Clunk From Front of Vehicle on Turns Bulletin No.: 05-02-35-003 Date: June 03, 2005 ADVANCED SERVICE INFORMATION Subject: ADVANCED SERVICE INFORMATION - EI-05061 I-Shaft Clunk or Stick-Slip Models: 2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005 GMC Sierra, Yukon, Yukon XL Attention: THIS IS NOT A RECALL. "GM of Canada" dealers are not authorized to use this bulletin. This bulletin ONLY applies to vehicles in which the customer has commented about this concern AND the E1 number shows in GMVIS. All others should disregard this bulletin and proceed with diagnostics found in published service information. Condition Important: If the customer did not bring their vehicle in for this issue, DO NOT proceed with this bulletin. Customers may comment about a "clunk" noise coming from the front of the vehicle. Correction GM Engineering is attempting to determine the root cause of I-Shaft replacements. There are three potential areas that may cause the customer's concern. GM Engineering is requesting that the three areas be evaluated before making any repairs. The three areas (listed in no particular order) that may cause the customer's concern are: ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined the cause of the concern is the I-Shaft, contact the following engineers who will want to evaluate the vehicle: IF IT IS DETERMINED THE CAUSE OF THE CUSTOMER'S CONCERN IS THE I-SHAFT, DO NOT MAKE ANY REPAIRS. CONTACT ONE OF THE FOLLOWING ENGINEERS WHO WILL COME TO THE DEALERSHIP TO EVALUATE THE CONCERN AND PROVIDE THE TECHNICIAN WITH REPAIR INSTRUCTIONS. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 05-02-35-003 > Jun > 05 > Body/Steering - Clunk From Front of Vehicle on Turns > Page 13821 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement - Upper Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement - Upper Intermediate Steering Shaft Replacement - Upper ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. Install the J 42640 in the steering column lower access hole. 2. Important: Mark the relationship of the intermediate shaft components in order to assure proper installation. Mark the relationships of the following components: ^ Mark the relationship of the bolt and clamp at both ends of the upper intermediate shaft. ^ Mark the relationship of the upper intermediate shaft to the lower intermediate shaft. 3. Remove the nut and bolt from the lower shaft to upper shaft connection. 4. Remove the nut and bolt (1) from the upper shaft (2) to steering column connection. 5. Slide the intermediate shaft down, out of the steering column connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement - Upper > Page 13824 6. Remove the accelerator pedal position sensor. 7. Slide the upper intermediate shaft towards the instrument panel, out of the lower intermediate shaft, and remove the shaft from the vehicle. Installation Procedure 1. Important: If you are installing the same shaft, align the marks and the relationship of the bolt and clamp made during the removal procedure. Install the lower end of the upper intermediate shaft through the bulkhead, into the lower shaft. 2. Install the upper end of the upper intermediate shaft (2) to the steering column. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt and nut (1) at the connection of the upper intermediate shaft to the steering column. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 4. Install the accelerator pedal position sensor. 5. Install the bolt and nut at the connection of the upper intermediate shaft to the lower intermediate shaft. ^ Tighten the nut to 47 Nm (35 ft. lbs.). 6. Remove the J 42640 from the steering column lower access hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement - Upper > Page 13825 Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement - Lower Intermediate Steering Shaft Replacement - Lower ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Caution: Refer to SIR Caution in Service Precautions. Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. 1. Set the front wheels in the straight-ahead position. 2. Install the J 42640 in the steering column lower access hole. 3. For vehicles equipped with a 6.6L Diesel, remove the left charge air cooler hose. 4. Mark the relationship of the intermediate shaft components in order to assure proper installation. 1. Mark the relationship of the upper intermediate shaft to the lower intermediate shaft. 2. Mark the relationship of the lower shaft coupler to the steering gear input shaft. 5. Remove the bolt from the upper to lower shaft connection. 6. Remove the bolt from the lower shaft coupler. 7. Remove the intermediate shaft assembly. Slide the shaft towards the dash in order to get the lower shaft coupler clear of the steering gear input shaft. 8. Slide the intermediate shaft down out of the upper shaft. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement - Upper > Page 13826 1. Install the upper end of the intermediate shaft into the upper shaft. 2. Install the lower end of the intermediate shaft coupler. 1. If you are reinstalling the same shaft, align the marks made during the removal procedure. 2. Install the lower end of the intermediate shaft coupler onto the steering gear worm shaft. 3. Install the bolt to the lower shaft coupler. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt to the upper end of the shaft. ^ Tighten the upper bolt to 47 Nm (35 ft. lbs.). ^ Tighten the coupler pinch bolt to 47 Nm (35 ft. lbs.). 5. For vehicles equipped with a 6.6L Diesel, remove the left charge air cooler hose. 6. Remove the J 42640 from the steering column lower access hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair Steering Wheel Replacement ^ Tools Required J 1859-A Steering Wheel Puller - J 36541-A Steering Wheel Puller Adapter - J 42578 Steering Wheel Puller Legs Removal Procedure 1. Disable the supplemental inflatable restraint (SIR) system. 2. Remove the inflator module. Refer to Horn Switch Replacement in SIR. 3. Remove the horn switch. Refer to Horn Switch Replacement. 4. Make an alignment mark in order to note the relationship of the steering wheel to the steering shaft. 5. Remove the steering wheel nut. 6. Remove the steering wheel using: ^ J 1859-A (1) with ^ J 36541-A (2) or J 42578 (2) Installation Procedure 1. Align the marks made during the removal of the steering shaft and the steering wheel. 2. Install the steering wheel onto the steering shaft. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the steering wheel nut to the steering shaft. ^ Tighten the nut to 40 Nm (29 ft. lbs.). 4. Install the horn switch. Refer to Horn Switch Replacement. 5. Install the inflator module. 6. Enable the SIR system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Power Steering System Tie Rod End: Service and Repair Power Steering System Rack and Pinion Outer Tie Rod End Replacement ^ Tools Required J 24319-01 Universal Steering Linkage Puller Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the torque prevailing nut from outer tie rod stud. 4. Loosen the jam nut (2) on the inner tie rod assembly (1). 5. Remove the outer tie rod assembly (2) from the steering knuckle (1) using J 24319-01. 6. Remove the outer tie rod assembly (3) from the inner tie rod assembly (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Power Steering System > Page 13835 Installation Procedure 1. Connect the outer tie rod assembly (3) to the inner tie rod (1). Do not tighten the jam nut (2). 2. Install the tie rod seal (2) to the outer tie rod assembly (1). 3. Connect the outer tie rod assembly (1) to the steering knuckle (2). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the torque prevailing nut (3) to the outer tie rod stud (1). ^ Tighten the torque prevailing nut (3) to 50 Nm (37 ft. lbs.). 5. Check the wheel alignment. Important: Be sure the rack and pinion boot is not twisted after the toe adjustment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Power Steering System > Page 13836 Tie Rod End: Service and Repair Rear Wheel Steering Rear Wheel Steering Tie Rod End Replacement - Outer ^ Tools Required J 24319-B Universal Steering Linkage Puller Removal Procedure Notice: Refer to Rear Wheel Steering Vehicle Lifting in Service Precautions. 1. Remove the tire and wheel. 2. Remove the outer tie rod retaining nut (1). 3. Loosen the tie rod jam nut (1). 4. Remove the nut retaining the outer tie rod end to the steering knuckle. 5. Using the J 24319-B (1), remove the outer tie rod end from the steering knuckle. 6. Remove the outer tie rod end from the inner tie rod. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Power Steering System > Page 13837 1. Install the outer tie rod end to the inner tie rod. 2. Install the outer tie rod end to the steering knuckle. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the outer tie rod retaining nut (1). ^ Tighten the nut to 55 Nm (40 ft. lbs.). 4. Install the tire and wheel. 5. Perform a four wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Gently lift or pry the suspension upward then let it settle. The dial indicator reading should be no more than 2 mm (0.079 inch). If the reading is out of specification, replace the ball joint. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection (Lower Ball Joint) Ball Joint: Testing and Inspection Ball Joint Inspection (Lower Ball Joint) Ball Joint Inspection (Lower Ball Joint) ^ Tools Required J 8001 Dial Indicator Set 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is present. If vertical free play is experienced proceed with the following instructions. 3. Remove the wheel and tire. 4. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. 5. Install and position the dial indicator from J 8001 against the end of the ball joint. 6. Gently lift or pry the suspension upward then let it settle. Important: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). 7. The dial indicator reading should be no more than 2 mm (0.079 inch). If the reading is out of specification, replace the ball joint. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection (Lower Ball Joint) > Page 13844 Ball Joint: Testing and Inspection Ball Joint Inspection (Upper Ball Joint) Ball Joint Inspection (Upper Ball Joint) ^ Tools Required J 8001 Dial Indicator Set 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is present. If vertical free play is experienced proceed with the following instructions. 3. Remove the wheel and tire. 4. Support the lower control arm with a floor stand or jack, as far outboard as possible. 5. If a seal is cut or torn, replace the ball joint. 6. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. 7. Check the wheel bearing for looseness in the wheel bearing is present, refer to Wheel Bearings Diagnosis. 8. Check the upper ball joint for vertical looseness. 9. Remove the lower shock absorber mounting bolt. This will ensure that the suspension is unloaded. 10. Install and position the dial indicator from J 8001 against the rim of the upper ball joint. 11. Apply downward force to the upper control arm and zero the indicator pointer/pad against the rim of the upper ball joint. 12. Release the arm and check the dial indicator. The dial indicator reading should be no more than 2 mm (0.079 inch). If the reading is too high, replace the upper control arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Ball Joint: Service and Repair Front Suspension (Coil Spring Suspension) Lower Ball Joint Replacement (Coil Spring Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 4. Secure the lower control arm in a bench vice or equivalent. 5. Center punch the rivet heads. 6. Drill out the rivets. 7. Remove the lower ball joint. Installation Procedure 1. Install the ball joint to the lower control arm. 2. Install the replacement bolts to the lower control arm. 3. Install the nuts to the bolts. ^ Tighten the nuts to 70 Nm (52 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the lower control arm from the bench vice. 5. Install the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 6. Install the tire and wheel tire assembly. 7. Remove the safety stands. 8. Lower the vehicle. 9. Verify the wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. (Torsion Bar Suspension) Lower Ball Joint Replacement (Torsion Bar Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 4. Place the lower control arm in a bench vice. 5. Using a chisel, remove the securing crimps from the ball joint body, if equipped. 6. Using a press, remove the ball joint from the lower control arm. Installation Procedure 1. Install the new ball joint using a press. Important: Use the outer flange of the ball joint in order to press the ball joint into place. 2. Place the lower control arm in a bench vice. 3. Using a punch, install crimps to the ball joint, if necessary. Use the replaced ball joint as a reference. 4. Install the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 5. Install the tire and wheel assembly. 6. Remove the safety stands. 7. Lower the vehicle. 8. Verify the wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 13847 Ball Joint: Service and Repair Rear Wheel Steering Upper Ball Joint Replacement Upper Ball Joint Replacement ^ Tools Required J 44664 Upper Ball Joint Nut Remover - J 44663 Upper Ball Joint Remover Removal Procedure Notice: Refer to Rear Wheel Steering Vehicle Lifting in Service Precautions. 1. Remove the tire and wheel. 2. Remove the bolt (2) retaining the brake hose bracket (1) to the axle. 3. Using the J 44664 (2), remove the nut (1) retaining the upper ball joint to the steering knuckle. 4. Remove the upper ball joint (3) retaining bolts (2) and stud (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 13848 5. Using the J 44663 (2), remove the upper ball joint stud from the steering knuckle. 6. Remove the upper ball joint (1) from the vehicle. Installation Procedure 1. Install the upper ball joint (1) to the steering knuckle. 2. Install the upper ball joint retaining bolts (2) and stud (1). ^ Tighten the bolts to 110 Nm (81 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nut (1) retaining the upper ball joint to the steering knuckle. Use the J 44664 (2) in order to tighten the joint. ^ Tighten the upper ball joint to the steering knuckle nut to 200 Nm (147 ft. lbs.). 4. Install the bracket (7) to the axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 13849 5. Install the bolt (2) retaining the brake hose bracket (1) to the axle. ^ Tighten the brake hose bracket retaining bolt to 12 Nm (106 inch lbs.). 6. Install the tire and wheel. 7. Perform a four wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Lower Ball Joint Replacement Lower Ball Joint Replacement Removal Procedure Notice: Refer to Rear Wheel Steering Vehicle Lifting in Service Precautions. 1. Remove the tire and wheel. 2. Remove the snap ring (2) from the ball joint stud (1). 3. Remove the bolts (2) retaining the lower ball joint (3) to the steering knuckle. 4. Remove the pinch bolt (1) retaining the lower ball. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 13850 5. Remove the lower ball joint (2) from the vehicle. Installation Procedure 1. Install the lower ball joint (2) to the vehicle. 2. Install the bolts (2) retaining the lower ball joint (3) to the steering knuckle. ^ Tighten the bolts to 110 Nm (81 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the lower ball joint pinch bolt (1). ^ Tighten the bolt to 230 Nm (169 ft. lbs.). 4. Install the snap ring (2) to the lower ball joint. 5. Install the tire and wheel. 6. Perform a four wheel alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement Control Arm: Technical Service Bulletins Suspension - Revised Upper Control Arm Replacement Bulletin No.: 06-03-08-002 Date: March 09, 2006 SERVICE MANUAL UPDATE Subject: Revised Upper Control Arm Replacement Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe Models 2003-2006 GMC Sierra, Yukon Models 2003-2006 HUMMER H2 This bulletin is being issued to revise the Upper Control Arm Replacement procedure in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Use of special tool J 42188-B eliminates the need to remove the wheel drive shaft on 4WD models. Upper Control Arm Replacement (Escalades, Avalanche, Silverado, Sierra, Suburban, Tahoe, Yukons) Tools Required J 42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Disconnect the electronic suspension control (ESC) link rod from the sensor, if equipped. Refer to Front Position Sensor Link Assembly - Electronic Suspension in Electronic Suspension Control. 4. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement > Page 13855 5. Remove the upper ball joint retaining nut. 6. Disconnect the upper control arm from the steering knuckle using the J 42188-B. 7. Remove the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 8. Remove the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 9. Remove the upper control arm nuts and the adjustment cams (2) for the 25/35 Series 4WD. 10. Remove the upper control arm bolts (4) for the 25/35 Series 4WD. 11. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement > Page 13856 2. Install the upper control arm bolts (4) for the 25/35 Series 4WD. Note: Refer to Fastener Notice in Cautions and Notices. 3. Install the upper control arm nuts and the adjustment cams (2) 25/35 Series 4WD. Tighten Tighten the nuts to 190 N.m (140 lb ft). 4. Install the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 5. Install the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. Tighten Tighten the nuts to 190 N.m (140 lb ft). 6. Connect the upper control arm to the steering knuckle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement > Page 13857 7. Install the new nut to the upper ball joint stud. Tighten Tighten the nut to 50 N.m (37 lb ft). 8. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten Tighten the bolts to 9 N.m (80 lb in). 9. Connect the ESC link rod to the sensor, if equipped. Refer to Front Position Sensor Link Assembly Replacement - Electronic Suspension in Electronic Suspension Control. 10. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 11. Remove the safety stands. 12. Lower the vehicle. 13. Verify the wheel alignment. Refer to Measuring Wheel Alignment in Wheel Alignment. Upper Control Arm Replacement (H2) Tools Required J 42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement > Page 13858 3. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. 4. Remove the nut at the upper ball joint. Discard the nut. 5. Disconnect the upper control arm from the steering knuckle using the J 42188-B. 6. Remove the upper control arm nuts and the adjustment cams. 7. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Note: Refer to Fastener Notice in Cautions and Notices. 2. Install the upper control arm bolts. Tighten Tighten the nuts to 190 N.m (140 lb ft). 3. Connect the upper control arm to the steering knuckle. 4. Install the new nut to the upper ball joint stud. Tighten Tighten the nut to 50 N.m (39 lb ft). 5. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten Tighten the bolts to 9 N.m (80 lb in). 6. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 7. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement > Page 13859 8. Verify the wheel alignment. Refer to Wheel Alignment Specifications in Wheel Alignment. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Page 13860 Control Arm: Specifications Lower Control Arm to Frame Nuts ...................................................................................................................................................... 175 Nm (129 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement Control Arm: Service and Repair Upper Control Arm Replacement The content of this article/image reflects the changes identified in TSB Bulletin No.: 06-03-08-002 Date: March 09, 2006 SERVICE MANUAL UPDATE Subject: Revised Upper Control Arm Replacement Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe Models 2003-2006 GMC Sierra, Yukon Models 2003-2006 HUMMER H2 Use of special tool J 42188-B eliminates the need to remove the wheel drive shaft on 4WD models. Upper Control Arm Replacement (Escalades, Avalanche, Silverado, Sierra, Suburban, Tahoe, Yukons) Tools Required J 42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Disconnect the electronic suspension control (ESC) link rod from the sensor, if equipped. Refer to Front Position Sensor Link Assembly Electronic Suspension in Electronic Suspension Control. 4. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13863 5. Remove the upper ball joint retaining nut. 6. Disconnect the upper control arm from the steering knuckle using the J 42188-B. 7. Remove the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 8. Remove the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 9. Remove the upper control arm nuts and the adjustment cams (2) for the 25/35 Series 4WD. 10. Remove the upper control arm bolts (4) for the 25/35 Series 4WD. 11. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13864 2. Install the upper control arm bolts (4) for the 25/35 Series 4WD. Note: Refer to Fastener Notice in Cautions and Notices. 3. Install the upper control arm nuts and the adjustment cams (2) 25/35 Series 4WD. Tighten Tighten the nuts to 190 N.m (140 lb ft). 4. Install the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 5. Install the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. Tighten Tighten the nuts to 190 N.m (140 lb ft). 6. Connect the upper control arm to the steering knuckle. 7. Install the new nut to the upper ball joint stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13865 Tighten Tighten the nut to 50 N.m (37 lb ft). 8. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten Tighten the bolts to 9 N.m (80 lb in). 9. Connect the ESC link rod to the sensor, if equipped. 10. Install the tire and wheel. 11. Remove the safety stands. 12. Lower the vehicle. 13. Verify the wheel alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13866 Control Arm: Service and Repair Lower Control Arm Replacement Lower Control Arm Replacement (4WD) ^ Tools Required ^ J 43631 Ball Joint Remover ^ J 45851 Ball Joint Separator Protector Adapters Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the stabilizer shaft links from the lower control arm. Refer to Stabilizer Shaft Replacement. 4. Remove the shock absorber lower nut and the bolt. Refer to Shock Absorber Replacement (4WD) Shock Absorber Replacement (RWD). 5. Remove the torsion bars. Refer to Torsion Bar Replacement. 6. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 7. Remove the lower ball joint retaining nut. 8. Disconnect the lower ball joint stud from the steering knuckle using J 43631 and J 45851. 9. Remove the lower control arm nuts and the 15-series washers. 10. Remove the lower control arm bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13867 11. Remove the lower control arm nuts and the 25/35-series washers. 12. Remove the lower control arm bolts. 13. Remove the lower control arm. Installation Procedure 1. Install the lower control arm. 2. Install the lower control arm 15-series bolts. 3. Install the lower control arm 25/35-series bolts. 4. Install the washers with the shoulder facing the arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13868 5. Install the lower control arm retaining nuts. ^ Tighten the nuts to 175 Nm (129 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 7. Connect lower ball joint stud to the steering knuckle. 8. Install the retaining nut to the lower ball joint stud. ^ Tighten the nut to 100 Nm (74 ft. lbs.). 9. Install the torsion bars. Refer to Torsion Bar Replacement. 10. Install the shock absorber lower nut and bolt. Refer to Shock Absorber Replacement (4WD) Shock Absorber Replacement (RWD). 11. Install the stabilizer shaft links to the lower control arm. Refer to Stabilizer Shaft Replacement. 12. Install the tire and wheel. 13. Remove the safety stands. 14. Lower the vehicle. 15. Align the vehicle. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > Customer Interest: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning Front Cross-Member: Customer Interest Body/Steering - Clunk Noise When Turning Bulletin No.: 05-02-35-003B Date: January 27, 2006 TECHNICAL Subject: EI05061 - Intermediate Steering Shaft Clunk Noise or Stick-Slip (Follow Strategy Based Diagnostics) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2006 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the diagnostic information. Please discard Corporate Bulletin Number 05-02-35-003A (Section 02 - Steering). Condition Some customers may comment on a "clunk" noise coming from the front of the vehicle. Correction Information has shown that the noise may be caused by the following three areas (listed in no particular order). Many of these concerns may initially be mis-diagnosed as an I-shaft clunk. ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined that the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined that the cause of the concern is the I-Shaft, follow the repair procedures/bulletins found in published Service Information (SI) concerning I-shaft lubing/replacement. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > Customer Interest: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning > Page 13878 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning Front Cross-Member: All Technical Service Bulletins Body/Steering - Clunk Noise When Turning Bulletin No.: 05-02-35-003B Date: January 27, 2006 TECHNICAL Subject: EI05061 - Intermediate Steering Shaft Clunk Noise or Stick-Slip (Follow Strategy Based Diagnostics) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2006 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the diagnostic information. Please discard Corporate Bulletin Number 05-02-35-003A (Section 02 - Steering). Condition Some customers may comment on a "clunk" noise coming from the front of the vehicle. Correction Information has shown that the noise may be caused by the following three areas (listed in no particular order). Many of these concerns may initially be mis-diagnosed as an I-shaft clunk. ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined that the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined that the cause of the concern is the I-Shaft, follow the repair procedures/bulletins found in published Service Information (SI) concerning I-shaft lubing/replacement. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning > Page 13884 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 13890 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member: > Page 13891 Front Cross-Member: By Symptom Technical Service Bulletin # 05-02-35-003B Date: 060127 Body/Steering - Clunk Noise When Turning Bulletin No.: 05-02-35-003B Date: January 27, 2006 TECHNICAL Subject: EI05061 - Intermediate Steering Shaft Clunk Noise or Stick-Slip (Follow Strategy Based Diagnostics) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2006 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the diagnostic information. Please discard Corporate Bulletin Number 05-02-35-003A (Section 02 - Steering). Condition Some customers may comment on a "clunk" noise coming from the front of the vehicle. Correction Information has shown that the noise may be caused by the following three areas (listed in no particular order). Many of these concerns may initially be mis-diagnosed as an I-shaft clunk. ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined that the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined that the cause of the concern is the I-Shaft, follow the repair procedures/bulletins found in published Service Information (SI) concerning I-shaft lubing/replacement. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member: > Page 13892 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-02-35-003B Date: 060127 Body/Steering - Clunk Noise When Turning Bulletin No.: 05-02-35-003B Date: January 27, 2006 TECHNICAL Subject: EI05061 - Intermediate Steering Shaft Clunk Noise or Stick-Slip (Follow Strategy Based Diagnostics) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2006 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the diagnostic information. Please discard Corporate Bulletin Number 05-02-35-003A (Section 02 - Steering). Condition Some customers may comment on a "clunk" noise coming from the front of the vehicle. Correction Information has shown that the noise may be caused by the following three areas (listed in no particular order). Many of these concerns may initially be mis-diagnosed as an I-shaft clunk. ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member: > Page 13893 To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined that the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined that the cause of the concern is the I-Shaft, follow the repair procedures/bulletins found in published Service Information (SI) concerning I-shaft lubing/replacement. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > Customer Interest for Front Cross-Member Bushing: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning Front Cross-Member Bushing: Customer Interest Body/Steering - Clunk Noise When Turning Bulletin No.: 05-02-35-003B Date: January 27, 2006 TECHNICAL Subject: EI05061 - Intermediate Steering Shaft Clunk Noise or Stick-Slip (Follow Strategy Based Diagnostics) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2006 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the diagnostic information. Please discard Corporate Bulletin Number 05-02-35-003A (Section 02 - Steering). Condition Some customers may comment on a "clunk" noise coming from the front of the vehicle. Correction Information has shown that the noise may be caused by the following three areas (listed in no particular order). Many of these concerns may initially be mis-diagnosed as an I-shaft clunk. ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined that the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined that the cause of the concern is the I-Shaft, follow the repair procedures/bulletins found in published Service Information (SI) concerning I-shaft lubing/replacement. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > Customer Interest for Front Cross-Member Bushing: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning > Page 13902 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning Front Cross-Member Bushing: All Technical Service Bulletins Body/Steering - Clunk Noise When Turning Bulletin No.: 05-02-35-003B Date: January 27, 2006 TECHNICAL Subject: EI05061 - Intermediate Steering Shaft Clunk Noise or Stick-Slip (Follow Strategy Based Diagnostics) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2006 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the diagnostic information. Please discard Corporate Bulletin Number 05-02-35-003A (Section 02 - Steering). Condition Some customers may comment on a "clunk" noise coming from the front of the vehicle. Correction Information has shown that the noise may be caused by the following three areas (listed in no particular order). Many of these concerns may initially be mis-diagnosed as an I-shaft clunk. ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined that the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined that the cause of the concern is the I-Shaft, follow the repair procedures/bulletins found in published Service Information (SI) concerning I-shaft lubing/replacement. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > 05-02-35-003B > Jan > 06 > Body/Steering - Clunk Noise When Turning > Page 13908 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > Page 13909 Front Cross-Member Bushing: By Symptom Technical Service Bulletin # 05-02-35-003B Date: 060127 Body/Steering - Clunk Noise When Turning Bulletin No.: 05-02-35-003B Date: January 27, 2006 TECHNICAL Subject: EI05061 - Intermediate Steering Shaft Clunk Noise or Stick-Slip (Follow Strategy Based Diagnostics) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2006 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the diagnostic information. Please discard Corporate Bulletin Number 05-02-35-003A (Section 02 - Steering). Condition Some customers may comment on a "clunk" noise coming from the front of the vehicle. Correction Information has shown that the noise may be caused by the following three areas (listed in no particular order). Many of these concerns may initially be mis-diagnosed as an I-shaft clunk. ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined that the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined that the cause of the concern is the I-Shaft, follow the repair procedures/bulletins found in published Service Information (SI) concerning I-shaft lubing/replacement. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > Page 13910 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-02-35-003B Date: 060127 Body/Steering - Clunk Noise When Turning Bulletin No.: 05-02-35-003B Date: January 27, 2006 TECHNICAL Subject: EI05061 - Intermediate Steering Shaft Clunk Noise or Stick-Slip (Follow Strategy Based Diagnostics) Models: 2005-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2006 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the diagnostic information. Please discard Corporate Bulletin Number 05-02-35-003A (Section 02 - Steering). Condition Some customers may comment on a "clunk" noise coming from the front of the vehicle. Correction Information has shown that the noise may be caused by the following three areas (listed in no particular order). Many of these concerns may initially be mis-diagnosed as an I-shaft clunk. ^ Body mount at the A-pillar - this noise may be heard mostly during a driving situation in which the body is twisted/flexed (i.e. hitting a pot-hole). ^ Frame - this noise may be heard at the torsion bar crossmember during a turning maneuver. ^ I-Shaft - this noise may be heard when turning at low speeds on rough road surfaces. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > Page 13911 To determine the source of the customer's concern, use chassis-ears to evaluate the body mount area and the frame torsion bar cross-member. An I-shaft concern can be felt as a "chucking" feel through the steering wheel. After the chassis-ears are installed, drive the vehicle to evaluate the customer's concern. If it is determined that the cause of the customer's concern is due to the body mount or torsion bar crossmember, proceed with the appropriate repair. If it is determined that the cause of the concern is the I-Shaft, follow the repair procedures/bulletins found in published Service Information (SI) concerning I-shaft lubing/replacement. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear Wheel Steering Front Steering Knuckle: Service and Repair Rear Wheel Steering Steering Knuckle Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller Removal Procedure Notice: Refer to Rear Wheel Steering Lifting and Jacking Notice in Service Precautions. 1. Remove the upper ball joint. 2. Remove the lower ball joint. 3. Remove the wheel hub and bearing. 4. Remove the outer tie rod retaining nut (1). 5. Disconnect the outer tie rod from the steering knuckle using the J 24319-B (1). 6. Remove the park brake cable retaining bolt (3) from the steering knuckle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear Wheel Steering > Page 13916 7. Remove the steering knuckle (2) from the vehicle. Installation Procedure 1. Install the steering knuckle (2) to the vehicle. 2. Install the upper ball joint. 3. Install the lower ball joint. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake cable retaining bolt (3) to the steering knuckle. ^ Tighten the bolt to 65 Nm (48 ft. lbs.). 5. Install the wheel hub and bearing. 6. Install the outer tie rod retaining nut (1). ^ Tighten the nut to 55 Nm (40 ft. lbs.). 7. Install the tire and wheel. 8. Perform a four wheel alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear Wheel Steering > Page 13917 Front Steering Knuckle: Service and Repair Front Steering Knuckle Replacement (4WD) ^ Tools Required ^ J 43631 Ball Joint Remover ^ J 45851 Ball Joint Separator Protector Adapters Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 4. Support the lower control arm with a suitable jack. 5. Disconnect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non- Rack and Pinion). 6. Remove the brake hose bracket retaining bolt from the steering knuckle. 7. Remove the upper control arm retaining nut and separate the upper ball joint from the steering knuckle using the J 43631 and J 45851. 8. Remove the lower control arm retaining nut. Separate the lower ball joint from the steering knuckle using the J 43631 and J 45851. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear Wheel Steering > Page 13918 9. Remove the steering knuckle. Installation Procedure 1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end. 2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, replace the steering knuckle. 3. Install the steering knuckle. 4. Notice: Refer to Fastener Notice in Service Precautions. Connect the lower ball joint to the steering knuckle and install the retaining nut. ^ Tighten the lower control arm retaining nut to 100 Nm (74 ft. lbs.). 5. Connect the upper ball joint to the steering knuckle and install the retaining nut. ^ Tighten the upper control arm retaining nut to 50 Nm (37 ft. lbs.). 6. Install the brake hose and the bracket retaining bolt to the steering knuckle ^ Tighten the bolt to 9 Nm (80 inch lbs.). 7. Connect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non-Rack and Pinion). 8. Install the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 9. Install the tire and wheel. 10. Remove the lower control arm support. 11. Lower the vehicle. 12. Align the vehicle. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear Wheel Steering > Page 13919 Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 13925 Steering Wheel Speed/Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Rear Steering System (Option) > Page 13926 Rear Wheel Position Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 13927 Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer to Rear Wheel Steering, Vehicle Lifting. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the electrical connector (1). 3. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 4. Remove the rear wheel position sensor retaining bolts (3). 5. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. Refer to Steering Gear Actuator and Cover Replacement. 6. Important: Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 13928 Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Lower the vehicle. 7. Perform a four wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams > Page 13932 Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension Stabilizer Bushing: Service and Repair Front Suspension Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the oil pan skid plate, if equipped. 4. Remove the stabilizer shaft insulator bracket bolts (3). 5. Remove the stabilizer shaft bracket (2). 6. Lower the stabilizer bar to remove the stabilizer shaft insulators (1). 7. Inspect all of the parts for wear and damage. Installation Procedure 1. Install the stabilizer shaft insulators (1) to the stabilizer shaft (4). Important: Place the insulators on the stabilizer shaft with the slits facing toward the front of the vehicle. 2. Install the stabilizer shaft (4) brackets (2) over the insulators. 3. Install stabilizer shaft insulator bracket bolts (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension > Page 13938 1. Tighten the bolts to 33 Nm (24 ft. lbs.), 15 series. 2. Tighten the bolts to 50 Nm (39 ft. lbs.), 25/35 series. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the stabilizer links. Refer to Stabilizer Shaft Link Replacement. 5. Install the oil pan skid plate, if equipped. ^ Tighten the oil pan skid plate retaining bolts to 20 Nm (15 ft. lbs.). 6. Install the tire and wheel assembly. 7. Remove the safety stands. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension > Page 13939 Stabilizer Bushing: Service and Repair Rear Suspension Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft insulator bracket mounting bolts, 15/25 series shown, 35 series similar. 3. Remove the stabilizer shaft insulators brackets. 4. Lower the stabilizer shaft and remove the stabilizer shaft insulators. 5. Inspect all of the parts for wear or damage. Installation Procedure 1. Important: Place the stabilizer shaft insulators on the stabilizer bar with the slits facing toward the front of the vehicle. Install the stabilizer shaft insulators to the stabilizer bar. 2. Install the stabilizer shaft insulator brackets to the rear axle, 15/25 series shown, 35 series similar. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the stabilizer shaft bracket mounting bolts. ^ Tighten the insulator bracket bolts to 33 Nm (24 ft. lbs.). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Suspension - Revised Stabilizer Link Service/Torque Stabilizer Link: Technical Service Bulletins Suspension - Revised Stabilizer Link Service/Torque Bulletin No.: 05-03-08-006 Date: April 12, 2005 SERVICE MANUAL UPDATE Subject: Revised Stabilizer Shaft Link Replacement Procedure and Fastener Tightening Specifications Models: 1999-2005 Chevrolet and GMC Full Size Pickup and Utility Models 2003-2005 HUMMER H2 This bulletin is being issued to revise the Stabilizer Shaft Link Replacement Procedure and Fastener Tightening Specifications in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following revision affects both the Fastener Tightening Specifications and the Stabilizer Shaft Link Replacement procedure. Pickup and Utility Models : Stabilizer Shaft Link Nuts - 10 Nm (89 lb in) Continue tightening the nut until 2 to 4 threads protrude above the nut. H2 : Stabilizer Shaft Link Nuts - 14 Nm (124 lb in) Continue tightening the nut until 2 to 4 threads protrude above the nut. The following Notice has been added to the Stabilizer Shaft Link Replacement procedure. Note: To avoid stabilizer shaft damage due to loss of clamp load, the threads of the link bolt must protrude 2 to 4 threads above the nut after the specified torque is achieved. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension Stabilizer Link: Service and Repair Front Suspension The content of this article reflects the changes identified in TSB 05-03-08-006. Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft nut (1) from the link bolt. 3. Remove the stabilizer shaft link bolt (3). 4. Remove the stabilizer shaft link insulators and spacers (2). 5. Inspect all of the parts for wear and damage. Installation Procedure 1. Install the stabilizer shaft link insulators and spacers (2). 2. Perform the following procedure before installing the stabilizer link bolts. ^ Remove all traces of the original adhesive patch. ^ Apply Threadlocker GM P/N 12345382 (Canadian P/N 10953489) BLUE LOCTITE # 242 on the threads of the bolts. 3. Install the stabilizer shaft link bolts (3). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the stabilizer shaft nut (1) to the link bolt. ^ Tighten the nut to 10 Nm (89 inch lbs.). Continue tightening the nut until 2-4 threads protrude above the nut. 5. Remove the safety stands. 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 13946 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Shaft Link Replacement (15/25 Series) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft link nut and bolt from the frame bracket. 3. Remove the stabilizer shaft link nut from the ball stud. 4. Remove the stabilizer shaft link. Installation Procedure 1. Install the stabilizer shaft link. 2. Install the stabilizer shaft link nut to the ball stud. Important: When tightening the lower link nut verify that the inner jam nut bottoms out on the ball stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 13947 3. Install the stabilizer shaft link nut and bolt to the frame bracket. Notice: Refer to Fastener Notice in Service Precautions. 1. Tighten the link to frame bracket nut to 65 Nm (48 ft. lbs.). 2. Tighten the ball stud to stabilizer shaft nut to 65 Nm (48 ft. lbs.). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Locations > Page 13952 Damping Control Actuator: Diagrams Shock Absorber Solenoid Valves - LF, RF Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Locations > Page 13953 Shock Absorber Solenoid Valves - LR, RR Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Diagrams Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Diagrams > Page 13957 Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Leaf Spring Bushing > Component Information > Service and Repair Leaf Spring Bushing: Service and Repair Spring Bushing Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the leaf spring assembly from vehicle. Refer to Leaf Spring Replacement. 3. Remove the bushing from the leaf spring using the following procedure: 1. Place the leaf spring in a press. 2. Press the bushing out. 3. Clean the spring bushing bore of any foreign or old bushing material. Installation Procedure 1. Apply rubber lubricant to the bushing (1) and spring eye (2). 2. Install the bushing to the leaf spring. 1. Place the leaf spring in a press. 2. Press the bushing into the spring. 3. Install the leaf spring assembly to the vehicle. Refer to Leaf Spring Replacement. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Service and Repair Shackle: Service and Repair Spring Shackle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the leaf spring assembly from vehicle. Refer to Leaf Spring Replacement. 3. Remove the shackle nut and the bolt from the spring. Installation Procedure 1. Install the shackle to the spring. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shackle nut and bolt to the spring. ^ Tighten the shackle nut to 95 Nm (70 ft. lbs.). 3. Install the leaf spring assembly to the vehicle. Refer to Leaf Spring Replacement. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-08-002B > Nov > 05 > Suspension Rattles/Squeaks From Front of Vehicle Suspension Strut / Shock Absorber: Customer Interest Suspension - Rattles/Squeaks From Front of Vehicle Bulletin No.: 03-03-08-002B Date: November 30, 2005 TECHNICAL Subject: Rattle/Squeak from Front of Vehicle (Replace Lower Portion of Upper Insulator Assembly) Models: 2002-2005 Cadillac Escalade, Escalade EXT 2003-2005 Cadillac Escalade ESV 2000-2005 Chevrolet Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 2000-2005 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the correction and parts information. Please discard Corporate Bulletin Number 03-03-08-002A (Section 03 - Suspension). Condition Some customers may comment on a rattle or squeak type noise coming from the front of the vehicle. Cause The front shock absorber plastic pilot ring may be wearing out, causing the shock to misalign in the insulator. Correction DO NOT replace the shock. Replace the lower portion, P/N 15834275 , of the upper insulator assembly using the procedure listed below. This new insulator has a taller plastic pilot ring that is attached to the metal sleeve to aid in the proper alignment of the insulators. 1. Remove the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. 2. Remove the lower portion of the upper insulator from the shock and discard. 3. Install the new lower portion of the upper insulator to the shock. Important: Be sure to center the shock in the frame bracket and tighten the upper mounting nut when the vehicle is on the ground. 4. Install the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-08-002B > Nov > 05 > Suspension Rattles/Squeaks From Front of Vehicle > Page 13973 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information > Page 13979 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 03-03-08-002B > Nov > 05 > Suspension - Rattles/Squeaks From Front of Vehicle Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Rattles/Squeaks From Front of Vehicle Bulletin No.: 03-03-08-002B Date: November 30, 2005 TECHNICAL Subject: Rattle/Squeak from Front of Vehicle (Replace Lower Portion of Upper Insulator Assembly) Models: 2002-2005 Cadillac Escalade, Escalade EXT 2003-2005 Cadillac Escalade ESV 2000-2005 Chevrolet Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 2000-2005 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the correction and parts information. Please discard Corporate Bulletin Number 03-03-08-002A (Section 03 - Suspension). Condition Some customers may comment on a rattle or squeak type noise coming from the front of the vehicle. Cause The front shock absorber plastic pilot ring may be wearing out, causing the shock to misalign in the insulator. Correction DO NOT replace the shock. Replace the lower portion, P/N 15834275 , of the upper insulator assembly using the procedure listed below. This new insulator has a taller plastic pilot ring that is attached to the metal sleeve to aid in the proper alignment of the insulators. 1. Remove the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. 2. Remove the lower portion of the upper insulator from the shock and discard. 3. Install the new lower portion of the upper insulator to the shock. Important: Be sure to center the shock in the frame bracket and tighten the upper mounting nut when the vehicle is on the ground. 4. Install the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 03-03-08-002B > Nov > 05 > Suspension - Rattles/Squeaks From Front of Vehicle > Page 13984 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information > Page 13990 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Page 13991 Suspension Strut / Shock Absorber: Specifications Shock Absorber Tension Nut (4WD) ....................................................................................................................................................... 20 Nm (15 ft. lbs.) Shock Absorber to Lower Control Arm Bolts (2WD) .............................................................................................................................. 25 Nm (18 ft. lbs.) Shock Absorber to Lower Control Arm Nut (4WD) ................................................................................................................................ 80 Nm (59 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Replacement Shock Absorber Replacement (4WD) Removal Procedure Notice: The front shock absorbers of the vehicle are multifunctional. In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended. Therefore, when servicing the shock absorber, service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength. Use of shocks not complying to original equipment or strength could result in suspension over-travel or shock breakage. Suspension over-travel may result in suspension component breakage. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the lower control arm with a jack stand. 3. If equipped with selectable ride, disconnect the electrical connector, with the following procedure: 1. Grasp the connector lock tabs (1,2). Rotate the connector tabs counterclockwise until the connector is unlocked. 2. Disengage the connector from the tension by firmly pulling the connector up. 3. Hold the tension end with a wrench while removing the nut. 4. Remove the nut. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 13994 4. Remove the upper insulator (1). Do not discard the plastic pilot ring (2). 5. Remove the shock absorber mounting bolt at the lower control arm, the 15 series. 6. The lower shock mounting bushing is serviceable by driving the bushing out with the appropriate tool. 7. Remove the shock absorber mounting bolt (2) at the lower control arm, the 25 series. 8. Remove the shock absorber. Installation Procedure 1. Install the shock absorber. Insert the stem through the hole in the shock bracket on the frame. 2. Align the shock absorber with the mounting holes in the lower control arm, the 15 series. 3. Align the shock absorber with the mounting holes in the lower control arm, the 25 series. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 13995 4. Install the shock absorber through the bolt (2) to the lower control arm. 5. Install the shock absorber through the bolt nut (3). ^ Tighten the nut to 80 Nm (59 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the upper insulator to the shock absorber. Important: The upper insulators are substantially larger that the lower insulators. The upper insulator (1) must be installed above the shock mounting bracket on the frame. The plastic pilot ring (2) will assist the alignment of the isolators. 7. Install the nut to the tension end. Do not tighten the nut. 8. Remove the safety stands. 9. Lower the vehicle. 10. Hold the tension end with a wrench while torquing the nut. ^ Tighten the nut to 20 Nm (15 ft. lbs.). 11. If equipped with selectable ride, connect the electrical connector using the following procedure: 1. Verify that the connector is unlocked. 2. Align the connector so that the tabs (1) are perpendicular to the wrench flats on the tension end. 3. Engage the connector to the tension by firmly pushing the connector down. 4. Grasp the connector lock tabs (1, 2). Rotate the connector counterclockwise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 13996 12. The connector is locked into place when you hear an audible snap and the tabs (1, 2) are aligned. 13. Dispose of the shock absorber. Refer to Shock Absorber Disposal. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 13997 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Shock Absorber Replacement Shock Absorber Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector if equipped with Selectable Ride. 3. Remove the upper shock absorber nut and the bolt. 4. Remove the lower shock absorber nut and the bolt. 5. Remove the shock absorber. Installation Procedure 1. Install the shock absorber. 2. Install the upper shock absorber nut and bolt. 3. Install the lower shock absorber nut and bolt. ^ Tighten the nuts to 95 Nm (70 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the electrical connector if equipped with Selectable Ride. 5. Remove the safety stands. 6. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 13998 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension Suspension Travel Bumper: Service and Repair Front Suspension Spring Bumper Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Unsnap the spring bumper from the mounting cup. For 4WD 15-Series and 2WD 25/35-Series. 3. Remove the nut from the spring bumper stud. For 4WD 15-Series and 2WD 25/35-Series. 4. Remove the spring bumper. Installation Procedure 1. Snap the spring bumper to the mounting cup. For 4WD 15-Series and 2WD 25/35-Series. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 14003 2. Install the spring bumper. For 4WD 15-Series and 2WD 25/35-Series. 3. Install the nut to the spring bumper stud. ^ Tighten the nut to 30 Nm (22 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 14004 Suspension Travel Bumper: Service and Repair Rear Suspension Spring Bumper Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the jounce bumper mounting bolt. 3. Remove the jounce bumper. The 15 series utilities are snap fit. Installation Procedure 1. Install the jounce bumper. The 15 series utilities are snap fit. 2. Install the jounce bumper bolt. ^ Tighten the bolt to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Remove the safety stands. 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement Torsion Bar: Service and Repair Torsion Bar Replacement Torsion Bar Replacement ^ Tools Required J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 2. Install the J 36202 to the adjustment arm and the crossmember. 3. Increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. 4. Remove the adjustment bolt (3) and the adjuster nut (4). Important: Mark the adjustment bolt and count the number of times that is required to remove the adjustment bolt. 5. Remove the adjustment bolt (3) and the adjuster nut (4), for vehicles with MN8, MT1 AND MW3. 6. Remove the J 36202 , allowing the torsion bar to unload. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 14009 7. Remove the adjustment arm by sliding the torsion bar forward until the torsion bar clears the adjustment arm. Use your hand to support the adjustment arm as the adjustment arm releases from the torsion bar. 8. Remove the torsion bar crossmember bolts (4) from the weld nuts (1). 9. Remove the upper link mounting nuts (1) and the bolts (2). 10. Remove the torsion bar crossmember. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 14010 11. Remove the torsion bars from the vehicle. Important: Note the position of the torsion bars as the left and right bars are different. Installation Procedure 1. Install the torsion bars to the lower control arm. 2. Install the torsion bar crossmember. 3. Install the torsion bar crossmember bolts (1) to the weld nuts (4). ^ Tighten the bolt to 95 Nm (70 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 14011 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the upper link mounting nuts and the bolts (3). ^ Tighten the nut to 95 Nm (70 ft. lbs.). 5. While supporting the adjustment arm, slide the torsion bar rearward until the torsion bar fully engages the adjustment arm. 6. Install the J 36202 to the adjustment arm and the crossmember. 7. Increase the tension on the adjustment arm in order to load the torsion bar. 8. Install the adjustment bolt (3) and the adjuster nut (4). Important: Install the adjustment bolt the same amount of turns that were required to remove the bolt during removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 14012 9. Install the adjustment bolt (3) and the adjuster nut (4), for vehicles with MN8, MT1 AND MW3. 10. Remove the J 36202 releasing the tension on the torsion bar until the load is taken up by the adjustment bolt. 11. Remove the safety stands. 12. Lower the vehicle. 13. Measure the Z height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. 14. Turn the adjustment bolt (2) clockwise to increase the Z height and counterclockwise to decrease the Z height. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 14013 Torsion Bar: Service and Repair Torsion Bars Bushing Replacement Torsion Bars Bushing Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Important: This procedure requires the removal of both torsion bars. 2. Remove the torsion bars. Refer to Torsion Bar Replacement. 3. Remove the bushing from the bracket utilizing a bushing driver or the equivalent. Installation Procedure 1. Install the bushing to the bracket utilizing a bushing driver or the equivalent. 2. Install the torsion bars. Refer to Torsion Bar Replacement. 3. Remove the safety stands. 4. Lower the vehicle. 5. Measure the Z height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. 6. Turn the adjustment bolt clockwise to increase the Z height and counterclockwise to lower the Z height. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 14018 Wheel Bearing: Fluid Type Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 14019 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 14020 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 14021 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 14022 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle Wheel Bearing: Service and Repair Rear Drive Axle Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting, See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the tire and wheel assembly, See: Wheels and Tires/Service and Repair 3. Remove the brake caliper bracket. It is not necessary to remove the brake caliper from the bracket. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 4. Remove the axle shaft, See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14025 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14026 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14027 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). - Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Turn the wheel hub over and seat the outer bearing assembly against the retaining ring using the J 24426 (2) and the J 8092 (1). 7. Ensure that the outer bearing assembly rotates freely in the hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14028 8. Turn the wheel hub over and install the inner bearing cup. 9. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). 10. Install the inner bearing. 11. Install the new oil seal using the J 44420 (2) and the J 8092 (1). Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. 12. Install the rotor, if necessary, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair 13. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14029 14. Install the wheel hub to the axle housing. 15. Install the adjusting nut to the hub using the J 2222-C. 16. Adjust the wheel bearings. Refer to Wheel Bearing Adjustment, See: Adjustments 17. Install the axle shaft, See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair 18. Install the brake caliper bracket, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 19. Install the tire and wheel assembly, See: Wheels and Tires/Service and Repair 20. Inspect and add axle lubricant to the axle housing, if necessary, See: Maintenance/Fluids/Fluid - Differential/Service and Repair 21. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14030 Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14031 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14032 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14033 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14034 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14035 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14036 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14037 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14038 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14039 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14040 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14041 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14042 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Install the wheel drive shaft retaining nut. Tighten the nut to ................................................................................................................................. ........................................... 250 Nm (184 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 14051 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 14052 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 14053 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 14054 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair > Page 14058 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair > Page 14059 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair > Page 14060 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 14065 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. FRAME CONTACT HOIST Front Hoist Pads IMPORTANT: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 14066 Position the front hoist pads under the front frame between the lower control arm and the frame pad. Rear Hoist Pads IMPORTANT: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger SUSPENSION CONTACT HOIST Front Lift Position the front lift under the outer edge of the front suspension lower control arms. Rear Lift Position the rear lift under the axle housing tubes on each side of the differential. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 14067 Do not damage the stabilizer bar. JACKING When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails IMPORTANT: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. JACK STANDS When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 14082 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 14096 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 14102 Spare Tire: Service and Repair Tire Hoist and Shaft Replacement Tire Hoist Secondary Latch Mechanism Important: If the spare tire hoist has been fully raised without a spare tire in place, the secondary latch mechanism may have become engaged. If this has occurred the hoist will not lower and the following steps will need to be followed: 1. Rotate the hoist shaft counterclockwise until approximately 15 cm (6 inch) of cable (1) is exposed. 2. While holding the latch pin (3), fully depress the latch button (2) and release the secondary latch from the hoist assembly. Some side-to-side and/or up-and-down movement may be necessary to disengage the latch mechanism. 3. Continue rotating the hoist shaft counterclockwise in order to lower the hoist the rest of the way. 4. If this does not release the secondary latch, the spare tire hoist will need to be replaced. See the following procedure. Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and using the ignition key, remove the lock. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 14103 2. Rotate the hoist shaft counterclockwise in order to lower the spare tire to the ground. Continue to rotate the shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. Notice: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by rotating the hoist shaft clockwise until you hear two clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by rotating the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, rotate the hoist shaft counterclockwise until approximately 15 cm (6 inch) of cable is exposed. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, rotate the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is NOT visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Vehicle Lifting. 6. Depress the tabs, remove the guide shaft from the hoist collar, and slide the shaft toward the bumper. 7. Remove the collar from the hoist 8. Remove the bolt. 9. Remove the hoist from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 14104 10. Remove the spare tire hoist shaft guide from the bumper. Installation Procedure 1. Install the spare tire hoist shaft guide to the bumper. 2. Install the hoist to the crossmember. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 4. Install the collar to the hoist 5. Install the shaft to the hoist. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 14105 6. Install the spare tire to the hoist. 7. Rotate the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. Notice: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 8. Remove the safety stands. 9. Lower the vehicle. 10. Install the spare tire stowage lock cylinder. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 14114 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 14115 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 14116 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 14121 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 14126 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 14127 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 14128 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: Customer Interest Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 14133 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 14139 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 14140 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 14141 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 14146 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 14151 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 14152 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 14157 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 14158 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 14159 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 14164 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 14169 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 14170 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 14171 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: All Technical Service Bulletins Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 14180 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM Wheels: All Technical Service Bulletins Wheels/Tires - 20 Inch Wheels Available From GM Bulletin No.: 03-03-10-006F Date: September 27, 2006 INFORMATION Subject: 20" Wheels Available Through GM Accessories Models: 1999-2007 Chevrolet Silverado 1500 Series Only (Classic) 1999-2007 GMC Sierra 1500 Series Only (Classic) Excludes 1999-2000 Vehicles with 4.3L Engine (VIN W - RPO L35) Excludes Vehicles with Quadrasteer (RPO NYS) Excludes Parallel Hybrid Truck (RPO HP2) Excludes 2001-2004 Vehicles with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14185 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14186 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14187 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14188 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14189 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14190 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14191 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14192 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 14198 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 14199 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 14200 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 14205 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 14210 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 14211 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM Wheels: All Technical Service Bulletins Wheels/Tires - 20 Inch Wheels Available From GM Bulletin No.: 03-03-10-006F Date: September 27, 2006 INFORMATION Subject: 20" Wheels Available Through GM Accessories Models: 1999-2007 Chevrolet Silverado 1500 Series Only (Classic) 1999-2007 GMC Sierra 1500 Series Only (Classic) Excludes 1999-2000 Vehicles with 4.3L Engine (VIN W - RPO L35) Excludes Vehicles with Quadrasteer (RPO NYS) Excludes Parallel Hybrid Truck (RPO HP2) Excludes 2001-2004 Vehicles with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14220 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14221 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14222 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14223 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14224 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14225 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14226 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 03-03-10-006F > Sep > 06 > Wheels/Tires - 20 Inch Wheels Available From GM > Page 14227 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. Important: Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M®, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 14230 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing A protective clear coating covers the surface of original equipment cast aluminum wheels. A surface degradation may develop if frequent automatic car wash cleaning wears off the factory applied protective clear coating. This can happen at some automatic car wash facilities that use aggressive brushes to clean whitewalls and tires. Once you damage the protective clear coating, exposure to caustic cleaners and road salt can cause further surface deterioration. Damage to the protective clear coating is corrected by replacing the damaged wheel. Refinishing is no longer recommended. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 14231 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Important: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. ^ Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel center cap. 3. Remove the wheel nuts from the tire and wheel. 4. Mark the location of the tire and wheel to the hub assembly. 5. Remove the tire and wheel from the vehicle. 6. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 14232 1. Install the tire and wheel. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. ^ Tighten the wheel nuts as shown to 190 Nm (140 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: ^ Tighten the nuts evenly and alternately in order to avoid excessive runout. 3. Install the wheel center cap. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 14237 Wheel Bearing: Fluid Type Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 14238 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 14239 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 14240 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 14241 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle Wheel Bearing: Service and Repair Rear Drive Axle Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting, See: Vehicle Lifting/Service and Repair 2. Remove the tire and wheel assembly, See: Service and Repair 3. Remove the brake caliper bracket. It is not necessary to remove the brake caliper from the bracket. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 4. Remove the axle shaft, See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14244 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14245 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14246 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). - Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Turn the wheel hub over and seat the outer bearing assembly against the retaining ring using the J 24426 (2) and the J 8092 (1). 7. Ensure that the outer bearing assembly rotates freely in the hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14247 8. Turn the wheel hub over and install the inner bearing cup. 9. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). 10. Install the inner bearing. 11. Install the new oil seal using the J 44420 (2) and the J 8092 (1). Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. 12. Install the rotor, if necessary, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair 13. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14248 14. Install the wheel hub to the axle housing. 15. Install the adjusting nut to the hub using the J 2222-C. 16. Adjust the wheel bearings. Refer to Wheel Bearing Adjustment, See: Adjustments 17. Install the axle shaft, See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair 18. Install the brake caliper bracket, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 19. Install the tire and wheel assembly, See: Service and Repair 20. Inspect and add axle lubricant to the axle housing, if necessary, See: Maintenance/Fluids/Fluid Differential/Service and Repair 21. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14249 Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14250 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14251 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14252 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14253 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14254 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14255 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14256 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14257 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14258 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14259 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14260 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Rear Drive Axle > Page 14261 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-002 > Mar > 05 > Wheels - Hubcaps Loose/Rattling Wheel Cover: Customer Interest Wheels - Hubcaps Loose/Rattling Info - Availability of New Functional Nut Caps For Steel Wheels # 05-03-10-002 - (Mar 21, 2005) Models: 2005 Chevrolet Silverado Models 2005 GMC Sierra Models with Steel Wheels Some vehicles may exhibit a condition of loose or rattling wheel hubcaps, especially on the front positions. This may be the result of brake heat distortion of the functional nut caps on the wheels. If this condition is encountered, only the functional nut caps in the hubcap assembly should be replaced, NOT the entire hubcap assembly. New functional nut caps, P/N 9596657, are now available. These new caps consist of more heat resistant material and are less susceptible to heat distortion. The new functional nut caps are dark gray in color. The original caps are black. Therefore, ALL functional nut caps on the vehicle must be replaced (24 functional nut caps on 6 bolt vehicles and 32 functional nut caps on 8 bolt vehicles). The old (black) functional nut caps should be snapped out of the hubcaps, and the new (dark gray) functional nut caps snapped back into place. When installing the hubcaps back on the vehicle, refer to Corporate Bulletin Number 03-03-10-002A. Use of Correct Installation Procedure for Loose Hubcap Assembly for the correct procedure for tightening the nut caps. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 03-03-10-002B > Nov > 05 > Wheels Correct Hub Cap Installation Procedure Wheel Cover: All Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 03-03-10-002B > Nov > 05 > Wheels Correct Hub Cap Installation Procedure > Page 14275 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 05-03-10-002 > Mar > 05 > Wheels Hubcaps Loose/Rattling Wheel Cover: All Technical Service Bulletins Wheels - Hubcaps Loose/Rattling Info - Availability of New Functional Nut Caps For Steel Wheels # 05-03-10-002 - (Mar 21, 2005) Models: 2005 Chevrolet Silverado Models 2005 GMC Sierra Models with Steel Wheels Some vehicles may exhibit a condition of loose or rattling wheel hubcaps, especially on the front positions. This may be the result of brake heat distortion of the functional nut caps on the wheels. If this condition is encountered, only the functional nut caps in the hubcap assembly should be replaced, NOT the entire hubcap assembly. New functional nut caps, P/N 9596657, are now available. These new caps consist of more heat resistant material and are less susceptible to heat distortion. The new functional nut caps are dark gray in color. The original caps are black. Therefore, ALL functional nut caps on the vehicle must be replaced (24 functional nut caps on 6 bolt vehicles and 32 functional nut caps on 8 bolt vehicles). The old (black) functional nut caps should be snapped out of the hubcaps, and the new (dark gray) functional nut caps snapped back into place. When installing the hubcaps back on the vehicle, refer to Corporate Bulletin Number 03-03-10-002A. Use of Correct Installation Procedure for Loose Hubcap Assembly for the correct procedure for tightening the nut caps. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 03-03-10-002B > Nov > 05 > Wheels - Correct Hub Cap Installation Procedure Wheel Cover: All Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 03-03-10-002B > Nov > 05 > Wheels - Correct Hub Cap Installation Procedure > Page 14285 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Install the wheel drive shaft retaining nut. Tighten the nut to ................................................................................................................................. ........................................... 250 Nm (184 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 14294 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 14295 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 14296 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 14297 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 05-03-10-002 > Mar > 05 > Wheels - Hubcaps Loose/Rattling Wheel Fastener: Customer Interest Wheels - Hubcaps Loose/Rattling Info - Availability of New Functional Nut Caps For Steel Wheels # 05-03-10-002 - (Mar 21, 2005) Models: 2005 Chevrolet Silverado Models 2005 GMC Sierra Models with Steel Wheels Some vehicles may exhibit a condition of loose or rattling wheel hubcaps, especially on the front positions. This may be the result of brake heat distortion of the functional nut caps on the wheels. If this condition is encountered, only the functional nut caps in the hubcap assembly should be replaced, NOT the entire hubcap assembly. New functional nut caps, P/N 9596657, are now available. These new caps consist of more heat resistant material and are less susceptible to heat distortion. The new functional nut caps are dark gray in color. The original caps are black. Therefore, ALL functional nut caps on the vehicle must be replaced (24 functional nut caps on 6 bolt vehicles and 32 functional nut caps on 8 bolt vehicles). The old (black) functional nut caps should be snapped out of the hubcaps, and the new (dark gray) functional nut caps snapped back into place. When installing the hubcaps back on the vehicle, refer to Corporate Bulletin Number 03-03-10-002A. Use of Correct Installation Procedure for Loose Hubcap Assembly for the correct procedure for tightening the nut caps. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 05-03-10-002 > Mar > 05 > Wheels Hubcaps Loose/Rattling Wheel Fastener: All Technical Service Bulletins Wheels - Hubcaps Loose/Rattling Info - Availability of New Functional Nut Caps For Steel Wheels # 05-03-10-002 - (Mar 21, 2005) Models: 2005 Chevrolet Silverado Models 2005 GMC Sierra Models with Steel Wheels Some vehicles may exhibit a condition of loose or rattling wheel hubcaps, especially on the front positions. This may be the result of brake heat distortion of the functional nut caps on the wheels. If this condition is encountered, only the functional nut caps in the hubcap assembly should be replaced, NOT the entire hubcap assembly. New functional nut caps, P/N 9596657, are now available. These new caps consist of more heat resistant material and are less susceptible to heat distortion. The new functional nut caps are dark gray in color. The original caps are black. Therefore, ALL functional nut caps on the vehicle must be replaced (24 functional nut caps on 6 bolt vehicles and 32 functional nut caps on 8 bolt vehicles). The old (black) functional nut caps should be snapped out of the hubcaps, and the new (dark gray) functional nut caps snapped back into place. When installing the hubcaps back on the vehicle, refer to Corporate Bulletin Number 03-03-10-002A. Use of Correct Installation Procedure for Loose Hubcap Assembly for the correct procedure for tightening the nut caps. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 14311 Wheel Fastener: Specifications Wheel Nut Torque ............................................................................................................................... ..................................................... 140 ft lb (190 Nm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 14312 Wheel Nut Torque Sequence Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel stud from the hub flange using the J 43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Refer to Brake Rotor Replacement Front in Disc Brakes. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 14315 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor, except dual wheel vehicles. 4. Remove the wheel stud from the axle flange using the J 43631. 5. Remove the axle shaft for vehicles with 9.5 in ring gear. 6. Remove the rear hub assembly for vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Remove the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Remove the wheel stud from the axle flange using the J 43631. 9. Remove the wheel stud from the hub flange using the J 43631. 10. Place the hub and rotor assembly in a press to remove the wheel stud. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 14316 1. Install the stud. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the axle shaft for the vehicles with 9.5 in ring gear. 6. Install the rear hub assembly for the vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Install the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Install the rotor, except dual wheels. 9. Install the tire and wheel. 10. Remove the safety stands. 11. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 14320 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 14321 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 14322 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair Accumulator HVAC: Service and Repair ACCUMULATOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Remove the nut from the evaporator tube (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Page 14327 5. Disconnect the electrical connector from the A/C low pressure switch. 6. Remove the compressor hose nut from the accumulator. 7. Remove the compressor hose from the accumulator. 8. Remove the nut (2) from the evaporator fitting. 9. Remove the accumulator bracket nut (4) from the retaining stud. 10. Remove the accumulator (3). 11. Remove the retaining bracket bolt (5). 12. Remove the retaining bracket (6) from the accumulator. 13. Remove and discard the O-ring seals. INSTALLATION PROCEDURE 1. Install new O-ring seals. 2. Install the retaining bracket (6) to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining bracket bolt (5). Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the accumulator (3). 5. Install the accumulator bracket nut (4). Tighten Tighten the nut to 9 N.m (80 lb in). 6. Install the nut (2) to the evaporator fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Page 14328 Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Install the compressor hose to the accumulator. 8. Install the compressor hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Connect the electrical connector to the A/C low pressure switch. 10. Install the nut to the evaporator tube (3). Tighten Tighten the nut to 25 N.m (18 lb ft). 11. Install the evaporator tube to the evaporator. 12. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 13. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 14. Leak test the fittings of the component using the J 39400-A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Air Door Actuator / Motor: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 14338 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Air Door Actuator / Motor: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 14344 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > HVAC Systems - Manual Air Door Actuator / Motor: Locations HVAC Systems - Manual HVAC Module Assembly - Top Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > HVAC Systems - Manual > Page 14347 HVAC Module Assembly - Bottom Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > HVAC Systems - Manual > Page 14348 Air Door Actuator / Motor: Locations HVAC Systems - Automatic Air Temperature Sensor - Lower Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > HVAC Systems - Manual > Page 14349 Air Temperature Sensor - Lower Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > HVAC Systems - Manual > Page 14350 HVAC Module Assembly - Bottom Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC Systems - Manual Air Door Actuator / Motor: Diagrams HVAC Systems - Manual Recirculation Actuator Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14353 Air Temperature Actuator - Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14354 Air Temperature Actuator - Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14355 Mode Actuator Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14356 Air Door Actuator / Motor: Diagrams HVAC Systems - Automatic Air Temperature Actuator - Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14357 Air Temperature Actuator - Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14358 Mode Actuator Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14359 Recirculation Actuator Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic Air Door Actuator / Motor: Service and Repair HVAC System - Automatic Air Temperature Actuator - Left AIR TEMPERATURE ACTUATOR REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the I/P insulator panel. 2. Disconnect the electrical connector (1) from the left air temperature actuator (2). 3. Remove the screws from the left air temperature actuator (2). 4. Remove the left air temperature actuator (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE 1. Install the left air temperature actuator (2) to the HVAC module assembly (3). 2. Install the screws to the left air temperature actuator (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 2 N.m (18 lb ft). 3. Install the electrical connector (1) to the left air temperature actuator (2). 4. Install the I/P insulator panel. 5. Reprogram the left air temperature actuator. Refer to Re-Calibrating Actuators. Air Temperature Actuator - Right AIR TEMPERATURE ACTUATOR REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the I/P carrier. 2. Disconnect the electrical connector (4) from the right air temperature actuator (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14362 3. Remove the screws from the right air temperature actuator (3). 4. Remove the right air temperature actuator (3) from the HVAC module assembly (2). INSTALLATION PROCEDURE 1. Install the right air temperature actuator (3) from the HVAC module assembly (2). 2. Install the screws to the right air temperature actuator (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the right air temperature actuator. 4. Install the I/P carrier. 5. Reprogram the air temperature actuator. Refer to Re-Calibrating Actuators. Mode Actuator (With RPO Code D07) MODE ACTUATOR REPLACEMENT (WITH RPO CODE D07) REMOVAL PROCEDURE 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Remove the center console. 3. Remove the screws from the center console duct. 4. Remove the center console duct. 5. Disconnect the electrical connection from the mode actuator (10). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14363 6. Remove the mode actuator mounting screws from the HVAC module. 7. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster valve lever with the mode actuator cam slot. - Line up the A/C valve lever with the mode actuator cam. 2. Install the mode actuator mounting screws to the HVAC module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connection at the mode actuator (10). 4. Install the center console duct. 5. Install the screws to the center console duct. Tighten the screws to 1.6 N.m (14 lb in). 6. Install the center console. 7. Install the floor air outlet duct extension (1) to the floor air duct (2). Mode Actuator (Without RPO Code D07) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14364 MODE ACTUATOR REPLACEMENT (WITHOUT RPO CODE D07) REMOVAL PROCEDURE 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Remove the body control module. 3. Disconnect the electrical connection at the mode actuator (10). 4. Remove the mode actuator mounting screws from the HVAC module. 5. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster lever with the mode actuator cam slot. - Line up the A/C lever with the mode actuator cam. 2. Install the mode actuator mounting screws to the HVAC module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.6 N.m (14 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14365 3. Connect the electrical connection at the mode actuator (10). 4. Install the body control module. 5. Install the floor air outlet duct extension (1) to the floor air duct (2). Recirculation Actuator RECIRCULATION ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air distribution duct. 2. Disconnect the electrical connection from the recirculation actuator (1). 3. Remove the recirculation actuator retaining screws. 4. Remove the recirculation actuator. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14366 1. Install the recirculation actuator. 2. Install the recirculation actuator retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector to the recirculation actuator (1). 4. Install the air distribution duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14367 Air Door Actuator / Motor: Service and Repair HVAC System - Manual Air Temperature Actuator AIR TEMPERATURE ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP insulator. 2. Disconnect the electrical connector (8) from the air temperature actuator (9). 3. Remove the air temperature actuator retaining screws. 4. Remove the air temperature actuator. INSTALLATION PROCEDURE 1. Install the air temperature actuator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14368 2. Install the air temperature actuator retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (8) to the air temperature actuator (9). 4. Install the IP insulator. Air Temperature Actuator - Left AIR TEMPERATURE ACTUATOR REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the I/P insulator panel. 2. Disconnect the electrical connector (1) from the left air temperature actuator (2). 3. Remove the screws from the left air temperature actuator (2). 4. Remove the left air temperature actuator (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE 1. Install the left air temperature actuator (2) to the HVAC module assembly (3). 2. Install the screws to the left air temperature actuator (2). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14369 Tighten the screws to 2 N.m (18 lb ft). 3. Install the electrical connector (1) to the left air temperature actuator (2). 4. Install the I/P insulator panel. 5. Reprogram the left air temperature actuator. Refer to Re-Calibrating Actuators. Air Temperature Actuator - Right AIR TEMPERATURE ACTUATOR REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the I/P carrier. 2. Disconnect the electrical connector (4) from the right air temperature actuator (3). 3. Remove the screws from the right air temperature actuator (3). 4. Remove the right air temperature actuator (3) from the HVAC module assembly (2). INSTALLATION PROCEDURE 1. Install the right air temperature actuator (3) from the HVAC module assembly (2). 2. Install the screws to the right air temperature actuator (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the right air temperature actuator. 4. Install the I/P carrier. 5. Reprogram the air temperature actuator. Refer to Re-Calibrating Actuators. Mode Actuator (With RPO Code D07) MODE ACTUATOR REPLACEMENT (WITH D07) REMOVAL PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14370 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Remove the center console. 3. Remove the screws from the center console duct. 4. Remove the center console duct. 5. Disconnect the electrical connection from the mode actuator (10). 6. Remove the mode actuator mounting screws from the HVAC module. 7. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster valve lever with the mode actuator cam slot. - Line up the A/C valve lever with the mode actuator cam. 2. Install the mode actuator mounting screws to the HVAC module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connection at the mode actuator (10). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14371 4. Install the center console duct. 5. Install the screws to the center console duct. Tighten the screws to 1.6 N.m (14 lb in). 6. Install the center console. 7. Install the floor air outlet duct extension (1) to the floor air duct (2). Mode Actuator (Without RPO Code D07) MODE ACTUATOR REPLACEMENT (WITHOUT D07) REMOVAL PROCEDURE 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Disconnect the electrical connection at the mode actuator (10). 3. Remove the mode actuator mounting screws from the HVAC module. 4. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14372 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster valve lever with the mode actuator cam slot. - Line up the A/C valve lever with the mode actuator cam. 2. Install the mode actuator mounting screw to the HVAC module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screw to 1.6 N.m (14 lb in). 3. Connect the electrical connection at the mode actuator (10). 4. Install the floor air outlet duct extension (1) to the floor air duct (2). Recirculation Actuator (Delphi) RECIRCULATION ACTUATOR REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. Remove the air distribution duct. 2. Disconnect the electrical connection from the recirculation actuator (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14373 3. Remove the recirculation actuator retaining screws. 4. Remove the recirculation actuator. INSTALLATION PROCEDURE 1. Install the recirculation actuator. 2. Install the recirculation actuator retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector to the recirculation actuator (1). 4. Install the air distribution duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair Air Door Cable: Service and Repair MODE CONTROL CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the radio. 2. Remove the heater control assembly. 3. Disconnect the mode cable from the heater/ventilation module. 4. Remove the mode cable from the IP carrier. INSTALLATION PROCEDURE 1. Install the mode cable to the IP carrier. 2. Connect the mode cable to the heater/ventilation module. 3. Install the heater control assembly. 4. Install the radio. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement Air Duct: Service and Repair Air Distributor Duct Replacement AIR DISTRIBUTOR DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP carrier. 2. Remove the air distribution duct retaining screws. 3. Remove the air distribution duct. INSTALLATION PROCEDURE 1. Install the air distribution duct. 2. Install the air distribution duct retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 4. Install the IP carrier. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 14381 Air Duct: Service and Repair Air Outlet Duct Replacement - Floor, LH AIR OUTLET DUCT REPLACEMENT - FLOOR, LH REMOVAL PROCEDURE 1. Remove the push pin (5) from the left floor air outlet duct (4). 2. Remove the left floor duct (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the left floor air outlet duct (1) to the HVAC module (2). 2. Install the push pin (2) to the left floor air outlet duct. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 14382 Air Duct: Service and Repair Air Outlet Duct Replacement - Floor, RH AIR OUTLET DUCT REPLACEMENT - FLOOR, RH REMOVAL PROCEDURE 1. Remove the right closeout/insulator panel. 2. Remove the screw from the right floor air outlet duct (3). 3. Remove the right floor air outlet duct (3) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the right floor air outlet duct (3) to the HVAC module (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screw to the right floor air outlet duct (3). Tighten Tighten the screw to 1.6 N.m (14 lb in). 3. Install the right closeout/insulator panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Deflector Replacement - Instrument Panel Air - Center Air Register: Service and Repair Deflector Replacement - Instrument Panel Air - Center DEFLECTOR REPLACEMENT - INSTRUMENT PANEL AIR - CENTER REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) bezel. 2. Remove the I/P trim panel. 3. Remove the deflector mounting screws. 4. Remove the deflector from the I/P. INSTALLATION PROCEDURE 1. Install the deflector to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the deflector mounting screws. Tighten Tighten the screw to 1.6 N.m (14 lb in). 3. Install the I/P trim panel. 4. Install the I/P bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Deflector Replacement - Instrument Panel Air - Center > Page 14387 Air Register: Service and Repair Deflector Replacement - Instrument Panel Air - Left DEFLECTOR REPLACEMENT - INSTRUMENT PANEL AIR - LEFT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) bezel. 2. Remove the knee bolster. 3. Remove the air deflector housing from the I/P by prying it out. 4. Disconnect the electrical connectors. 5. Remove the air deflector screws. 6. Remove the air deflector from the housing. INSTALLATION PROCEDURE 1. Install the air deflector to the housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connectors. 4. Install the air deflector assembly to the I/P. 5. Remove the knee bolster. 6. Install the I/P bezel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Deflector Replacement - Instrument Panel Air - Center > Page 14388 Air Register: Service and Repair Deflector Replacement - Instrument Panel Air - Right DEFLECTOR REPLACEMENT - INSTRUMENT PANEL AIR - RIGHT REMOVAL PROCEDURE 1. Use a flat blade tool in order to remove the deflector from the instrument panel. 2. Remove the deflector. INSTALLATION PROCEDURE 1. Align the deflector into the opening in the instrument panel. 2. Push the deflector into the instrument panel until the deflector snaps into place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Air Temperature Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 14392 Ambient Air Temperature Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 14393 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Trunk Zoning TRUCK ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14399 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14400 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14401 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14402 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14403 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14404 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14405 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14406 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14407 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14408 necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14409 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14410 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14411 showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 Volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14412 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 Volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 Volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through.This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing For Proper Terminal Contact Tools Required J 35616-C GM-Approved Terminal Test Kit - J 38125 Terminal Repair Kit It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616- C when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14413 Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. Temperature Sensitivity An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. Incorrect Control Module There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14414 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14415 When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14416 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14417 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14418 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14419 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J 38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14420 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14421 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14422 TOOLS REQUIRED J 38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14423 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14424 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14425 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14426 locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14427 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14428 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J 38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14429 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14430 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J 38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14431 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14432 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14433 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J 38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14434 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J 38125-D to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J 38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14435 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14436 TOOLS REQUIRED J 38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J 38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J 38125-D. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14437 - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14438 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14439 The J 38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J 38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J 38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14440 7. Use the Splice Crimp Tool from the J 38125-D in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14441 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14442 The tool kit J 38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14443 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in)away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D to crimp splice sleeve. In order to position the splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14444 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14445 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14446 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125 Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14447 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14448 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14449 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14450 Equivalents - Decimal And Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14451 Equivalents - Decimal And Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14452 Various symbols in order to describe different service operations. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14453 Conversion - English/Metric Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14454 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14455 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14456 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14457 The Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) are as shown in the table. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE TOOL AND EQUIPMENT GROUP KENT-MOORE 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: DEALER EQUIPMENT SERVICES 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14458 8:00 am-6:00 pm EST Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14459 The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14460 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14461 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14462 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14463 "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14464 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14465 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14466 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14467 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14468 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14469 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14470 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14471 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14472 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14473 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 14474 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Blower Motor Impeller > Component Information > Service and Repair Blower Motor Impeller: Service and Repair BLOWER MOTOR IMPELLER REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the sound insulator panel. 2. Disconnect the electrical connector (2) from the blower motor (1). 3. Remove the screws from the blower motor (1). 4. Remove the blower motor (1) from the HVAC module (3). 5. Remove the retainer from the blower motor impeller. Discard the retainer. 6. Remove the blower motor impeller from the blower motor (1). INSTALLATION PROCEDURE 1. Install the blower motor impeller to the blower motor (1). 2. Install the new retainer to the blower motor impeller. 3. Install the blower motor (1) to the HVAC module (3). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the blower motor (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Connect the electrical connector (2) to the blower motor (1). 6. Install the sound insulator panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 14486 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 14487 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only Blower Motor Resistor: Customer Interest A/C - Blower Motor Inop. or Works On Low Speed Only Bulletin No.: 05-01-38-012C Date: November 02, 2006 TECHNICAL Subject: EI05082 - Loss of Blower Motor Speeds Except for Low Speed or Inoperative (Replace Blower Motor Resistor and Resistor Module Connector) Models: 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2007 Chevrolet Silverado (Classic) Built Prior to September 1, 2006 2004-2006 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL 2007 GMC Sierra (Classic) Built Prior to September 1, 2006 with HVAC System AC Front, Manual Temp Control (RPO CJ3) or Heater Only (RPO C42) Supercede: This bulletin is being revised to clarify the Warranty Information. Please discard Corporate Bulletin Number 05-01-38-012B (Section 01 - HVAC). Condition Some customers may comment that the blower will only work on low speeds or has become inoperative. Correction REPLACE THE BLOWER MOTOR RESISTOR AND RESISTOR MODULE CONNECTOR. Replace the blower motor resistor and module connector using the following procedure: Remove the blower fuse. Fullsize Trucks and Utility Vehicles - Htr A/C & HVAC 1 fuses Midsize Utility Vehicles - Blower Fuse 35 located in the Underhood Fuse Block Lower the hush panel or close-out panel enough to gain access to the resistor module connector. Disconnect the connector from the resistor module. Remove the tape from the wiring harness to expose the wiring. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only > Page 14493 Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Tip Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Install the new connector. Use the yellow splice sleeves provided with the connector. Install new blower motor resistor. Reinstall the fuse or connector block. Test the blower motor to make sure all speeds are functional. Reinstall the hush panel/close-out panel. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only > Page 14494 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously > Page 14500 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously > Page 14501 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only Blower Motor Resistor: All Technical Service Bulletins A/C - Blower Motor Inop. or Works On Low Speed Only Bulletin No.: 05-01-38-012C Date: November 02, 2006 TECHNICAL Subject: EI05082 - Loss of Blower Motor Speeds Except for Low Speed or Inoperative (Replace Blower Motor Resistor and Resistor Module Connector) Models: 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2007 Chevrolet Silverado (Classic) Built Prior to September 1, 2006 2004-2006 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL 2007 GMC Sierra (Classic) Built Prior to September 1, 2006 with HVAC System AC Front, Manual Temp Control (RPO CJ3) or Heater Only (RPO C42) Supercede: This bulletin is being revised to clarify the Warranty Information. Please discard Corporate Bulletin Number 05-01-38-012B (Section 01 - HVAC). Condition Some customers may comment that the blower will only work on low speeds or has become inoperative. Correction REPLACE THE BLOWER MOTOR RESISTOR AND RESISTOR MODULE CONNECTOR. Replace the blower motor resistor and module connector using the following procedure: Remove the blower fuse. Fullsize Trucks and Utility Vehicles - Htr A/C & HVAC 1 fuses Midsize Utility Vehicles - Blower Fuse 35 located in the Underhood Fuse Block Lower the hush panel or close-out panel enough to gain access to the resistor module connector. Disconnect the connector from the resistor module. Remove the tape from the wiring harness to expose the wiring. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only > Page 14506 Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Tip Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Install the new connector. Use the yellow splice sleeves provided with the connector. Install new blower motor resistor. Reinstall the fuse or connector block. Test the blower motor to make sure all speeds are functional. Reinstall the hush panel/close-out panel. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only > Page 14507 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only Blower Motor Resistor: All Technical Service Bulletins A/C - Blower Motor Inop. or Works On Low Speed Only Bulletin No.: 05-01-38-012C Date: November 02, 2006 TECHNICAL Subject: EI05082 - Loss of Blower Motor Speeds Except for Low Speed or Inoperative (Replace Blower Motor Resistor and Resistor Module Connector) Models: 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2007 Chevrolet Silverado (Classic) Built Prior to September 1, 2006 2004-2006 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL 2007 GMC Sierra (Classic) Built Prior to September 1, 2006 with HVAC System AC Front, Manual Temp Control (RPO CJ3) or Heater Only (RPO C42) Supercede: This bulletin is being revised to clarify the Warranty Information. Please discard Corporate Bulletin Number 05-01-38-012B (Section 01 - HVAC). Condition Some customers may comment that the blower will only work on low speeds or has become inoperative. Correction REPLACE THE BLOWER MOTOR RESISTOR AND RESISTOR MODULE CONNECTOR. Replace the blower motor resistor and module connector using the following procedure: Remove the blower fuse. Fullsize Trucks and Utility Vehicles - Htr A/C & HVAC 1 fuses Midsize Utility Vehicles - Blower Fuse 35 located in the Underhood Fuse Block Lower the hush panel or close-out panel enough to gain access to the resistor module connector. Disconnect the connector from the resistor module. Remove the tape from the wiring harness to expose the wiring. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only > Page 14513 Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Tip Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Install the new connector. Use the yellow splice sleeves provided with the connector. Install new blower motor resistor. Reinstall the fuse or connector block. Test the blower motor to make sure all speeds are functional. Reinstall the hush panel/close-out panel. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only > Page 14514 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 14520 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 14521 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 14522 HVAC Module Assembly - Bottom Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 14523 Blower Motor Resistor Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement BLOWER MOTOR RESISTOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the IP sound insulator. 2. Disconnect the electrical connection from the blower motor. 3. Disconnect the electrical connection from the blower motor resistor. 4. Remove the blower motor resistor retaining screws. 5. Remove the blower motor resistor. INSTALLATION PROCEDURE Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 14526 1. Install the blower motor resistor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor resistor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connection to the blower motor resistor. 4. Connect the electrical connection to the blower motor. 5. If equipped, install the IP sound insulator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 14527 Blower Motor Resistor: Service and Repair Blower Motor Replacement (Delphi) BLOWER MOTOR REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. If equipped, remove the sound insulator panel. 2. Remove the blower motor insulating cover screws. 3. Disconnect the electrical connector from the blower motor. 4. Remove the blower motor insulating cover. 5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 14528 6. Remove the blower motor. INSTALLATION PROCEDURE 1. Install the blower motor. 2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place. 3. Install the blower motor insulating cover. 4. Connect the electrical connector to the blower motor. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the blower motor insulating cover screws. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 14529 Tighten Tighten the screws to 1.6 N.m (14 lb in). 6. If equipped, install the sound insulator panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 14530 Blower Motor Resistor: Service and Repair Blower Motor Replacement (Visteon) BLOWER MOTOR REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the sound insulator panel. 2. Disconnect the electrical connector (2) from the blower motor (1). 3. Remove the screws from the blower motor (1). 4. Remove the blower motor (1) from the HVAC module (3). 5. Remove the retainer from the blower motor impeller. Discard the retainer. 6. Remove the blower motor impeller from the blower motor (1). INSTALLATION PROCEDURE 1. Install the blower motor impeller to the blower motor (1). 2. Install the new retainer to the blower motor impeller. 3. Install the blower motor (1) to the HVAC module (3). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the blower motor (1) Tighten Tighten the screws to 2 N.m (18 lb in). 5. Connect the electrical connector (2) to the blower motor (1). 6. Install the sound insulator panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This Article has been updated by bulletin #PIT3330, dated December 22, 2004. Condition/Concern: A customer may inquire about the availability of the passenger compartment air filter. Recommendation/Instructions: Starting in 2003 model year, the passenger compartment air filter is no longer available as a factory option. With the redesigned HVAC case, there is no longer a cavity for the filter. The GM parts catalog indicates there is a replacement filter available; however, there is no provision for it. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations Upper Left B-Pillar Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 14537 Air Temperature Sensor Assembly - Inside Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 14538 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 14539 7. Install the left windshield garnish molding. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure Use a flat-bladed tool to pry the pressure release valve from the cab back panel. Remove the pressure relief valve from the vehicle. Installation Procedure Align the pressure relief valve into the opening of the rear cab. Press the Pressure Relief Valve into the Cab Back Panel until the locking tabs are fully seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure Use a flat-bladed tool to pry the pressure release valve from the cab back panel. Remove the pressure relief valve from the vehicle. Installation Procedure Align the pressure relief valve into the opening of the rear cab. Press the Pressure Relief Valve into the Cab Back Panel until the locking tabs are fully seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams A/C Compressor Clutch Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Specifications Compressor Clutch Hub: Specifications Clutch Plate Air Gap ........................................................................................................................................................... 0.35-0.65 mm (0.014 - 0.026 in) Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Specifications > Page 14553 Compressor Clutch Hub: Service and Repair Compressor Clutch Plate/Hub Assembly Replacement (4.8L, 5.3L, 6.0L and 8.1L) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. 3. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt. 5. Remove the A/C belt from the A/C compressor. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the clutch plate retaining bolt (1). 8. Remove the clutch plate assembly (2). 9. Remove the clutch hub/bearing snap ring (3). 10. Remove the clutch hub/bearing assembly (4). 11. Remove the snap ring (5) from the clutch coil (6). 12. Remove the clutch coil (6) from the A/C compressor (7). Installation Procedure 1. Install the clutch coil (6) to the A/C compressor (7). 2. Install the snap ring (5) to the clutch coil (6). 3. Install the clutch hub/bearing assembly (4). 4. Install the clutch hub/bearing snap ring (3). 5. Place a small amount of oil on the thinnest air gap shim and place it inside the clutch plate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Specifications > Page 14554 6. Install the clutch plate assembly (2). Important: Ensure the drive plate does not drag against the pulley when the pulley is rotated. 7. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.35-0.65 mm (0.014-0.026 in) air gap. Notice: Refer to Fastener Notice. 8. Install the clutch plate retaining bolt (1). Tighten the bolt to 18 N.m (13 lb ft). 9. Install a ratchet into the A/C belt tensioner adapter opening. 10. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt. 11. Install the A/C belt to the A/C compressor. 12. Slowly release the tension on the A/C belt tensioner. 13. Remove the ratchet from the A/C belt tensioner. 14. Install the engine protection shield. 15. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair CONDENSER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the grille. 3. Remove the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support. 4. Remove the lower bolts from the hood latch support bracket. 5. Remove the compressor discharge hose assembly bolt from the condenser. 6. Disconnect the compressor discharge hose assembly from the condenser. 7. Remove the evaporator tube nut from the condenser. 8. Disconnect the evaporator tube from the condenser. 9. Remove the insulator retainer bolts and the upper insulator retainers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 14558 10. Remove the condenser from the vehicle. INSTALLATION PROCEDURE IMPORTANT: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities for system capacity information. 1. Install the condenser to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper insulator retainers and the insulator retainer bolts. Tighten Tighten the bolts to 2.4 N.m (21 lb in). 3. Connect the evaporator tube to the condenser using new sealing washers. 4. Install the evaporator tube nut to the condenser. Tighten Tighten the evaporator tube nut to 16 N.m (12 lb ft). 5. Connect the compressor discharge hose to the condenser using new sealing washers. 6. Install the compressor discharge hose nut to the condenser Tighten Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 14559 Tighten the compressor discharge hose nut to 16 N.m (12 lb ft). 7. Install the lower bolts to the hood latch support bracket. Tighten Tighten the compressor discharge hose nut to 9 N.m (80 lb in). 8. Install the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support. Tighten Tighten the compressor discharge hose nut to 9 N.m (80 lb in). 9. Install the grille. 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the component using the J 39400-A. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations HVAC Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 14563 HVAC Module Assembly - Top Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual Control Assembly: Diagrams HVAC Systems - Manual HVAC Control Module - C1 Part 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14566 HVAC Control Module - C1 Part 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14567 HVAC Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14568 Control Assembly: Diagrams HVAC Systems - Automatic HVAC Control Module - C1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 14569 HVAC Control Module - C2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC System - Automatic Control Assembly: Service and Repair HVAC System - Automatic HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control module. 3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the HVAC control module. IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place. 3. Install the screws from the HVAC control module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel accessory trim plate. 5. Start the vehicle and let run for one minute. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 14572 Control Assembly: Service and Repair HVAC System - Manual HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim plate bezel. 2. Remove the instrument panel storage tray. 3. Remove the accessory switch assembly from the instrument panel. 4. Remove the screws from the HVAC control assembly. 5. Remove the HVAC control assembly, with the following procedure: 1. Release the retaining tabs. 2. Pull the control head out of the instrument panel carrier. 6. Disconnect the electrical connectors from the HVAC control assembly. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the HVAC control assembly. IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 2. Install the HVAC control assembly. 3. Install the accessory switch assembly to the instrument panel. 4. Install the screws from the HVAC control assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.9 N.m (17 lb in). 5. Install the instrument panel storage tray. 6. Install the instrument cluster trim plate bezel. 7. Start the vehicle and let run for one minute. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 14581 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 14582 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 14588 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously > Page 14594 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously > Page 14595 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C Ticking Noise From Instrument Panel/DTC's Set > Page 14600 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C Ticking Noise From Instrument Panel/DTC's Set > Page 14606 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-5.3L VIN Z Flex Fuel (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 14612 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: